Electrode assembly cutting device and separator cutting device

ABSTRACT

A device for manufacturing a laminated electrode comprises: a negative electrode cutting drum that forms a negative electrode sheet by cutting a negative electrode single sheet to a first width and conveys the negative electrode sheet; a negative electrode heating drum that heats the negative electrode sheet; a positive electrode cutting drum that forms a positive electrode sheet by cutting a positive electrode single sheet to a second width and conveys the positive electrode sheet; a positive electrode heating drum that heats the positive electrode sheet; and a bonding drum at which the negative electrode sheet is arranged on a first separator single sheet, a second separator single sheet is arranged on the negative electrode sheet, the positive electrode sheet is arranged on the second separator single sheet, and the sheets are bonded. The negative and positive electrode cutting drums include: a plurality of holding heads and pairs of blades.

TECHNICAL FIELD

The present disclosure relates to an electrode assembly cutting deviceand a separator cutting device.

BACKGROUND ART

Since a large capacity, low internal resistance and a high heatradiation performance are requested in an in-vehicle lithium ionsecondary battery or the like for example, a laminate type battery whichcan satisfy the requests has been developed. The battery is in a formthat a positive electrode, a separator and a negative electrode arealternately laminated, the respective electrodes are connected to ametal terminal called a tab and put in a container configured by analuminum laminate film, an electrolyte is injected and sealing isperformed.

Patent Literature 1 describes that there are: an electrode supportsection that receives an electrode supplied by a conveying device andsupports the electrode; a circulation member which has a loop shapeextending in a vertical direction, and on the outer peripheral surfaceof which the electrode support section is attached; a lamination unitthat is disposed on a side opposite to the conveying device with thecirculation member interposed therebetween, and includes a plurality ofstages of lamination sections where the electrode is laminated; anextrusion section that simultaneously extrudes the electrodes supportedby the plurality of electrode support sections toward the plurality ofstages of lamination sections; and a control section that controlscirculation and elevation of the circulation member and an operation ofthe extrusion section, and the control section controls the operation ofthe extrusion section so as to extrude the electrodes toward thelamination sections at a speed lower than a conveying speed of theelectrodes by the conveying device.

Patent Literature 2 describes that a device which manufactures alaminated electrode assembly for which a positive electrode and anegative electrode are alternately laminated holding a separatortherebetween comprises: a winding drum having an outer peripheralsurface around which a continuously delivered separator sheet can bewound; and an electrode supply unit which supplies the electrodesuccessively at intervals such that the positive electrode and thenegative electrode can be switched, to a valley formed between aseparator sheet SS wound around the outer peripheral surface and aseparator sheet to be wound around the outer peripheral surface.

Patent Literature 3 describes that raw materials are a continuouspositive electrode material, a continuous negative electrode materialand a continuous separator material for which positive electrodes,negative electrodes and separators are continuously formed viaeasy-to-cut breaking lines respectively, there are roughly cylindricalwinding means that wind a continuous battery material formed by pilingup the respective raw materials in the order of the continuous separatormaterial, the continuous positive electrode material, the continuousseparator material and the continuous negative electrode material or inthe order of the continuous separator material, the continuous negativeelectrode material, the continuous separator material and the continuouspositive electrode material while the respective breaking lines are madeto coincide with one another, pressing means that press the woundcontinuous battery material to a side peripheral surface of the windingmeans, and cutting means that cut the continuous battery material ateach breaking line after the continuous battery material is wound aroundthe winding means for a required number of laminations, and for thecutting means, a part of the side peripheral surface of the windingmeans in a circumferential direction is projected in a radial direction.

CITATION LIST Patent Literature

PATENT LITERATURE 1: International Publication No. WO 2017/131027

PATENT LITERATURE 2: Japanese Unexamined Patent Application PublicationNo. 2012-199211 PATENT LITERATURE 3: Japanese Unexamined PatentApplication Publication No. 2011-86508 SUMMARY

In order to efficiently manufacture a laminated electrode assemblyformed by alternately laminating a positive electrode, a separator and anegative electrode, it is needed to supply a belt-like positiveelectrode body and a belt-like negative electrode body to a drum, obtaina positive electrode plate and a negative electrode plate by cutting thebelt-like positive electrode body and negative electrode body intodesired sizes respectively, and successively laminate them at desiredpositions.

It is an object of the present disclosure to provide a technologycapable of efficiently cutting a rectangular electrode assemblyconfiguring a laminated electrode assembly when manufacturing thelaminated electrode assembly.

One aspect of the present disclosure comprises: a plurality of holdingheads arranged in a circumferential direction of a drum and rotatedaround a drum center axis holding a rectangular electrode assembly; andcutting means provided in each of the plurality of holding heads andconfigured to cut the rectangular electrode assembly in a predeterminedwidth, and the cutting means comprise a pair of blades arranged in athickness direction of the rectangular electrode assembly so as to holdthe rectangular electrode assembly therebetween.

In another aspect of the present disclosure, the pair of bladesmaintains a distance so as not to overlap with each other in thethickness direction of the rectangular electrode assembly and cuts therectangular electrode assembly.

In a further aspect of the present disclosure, a distance L of the pairof blades in the thickness direction of the rectangular electrodeassembly and a thickness d of the electrode assembly satisfy d>L≥0.

In a still further aspect of the present disclosure, the rectangularelectrode assembly comprises a current collector and an active materiallayer formed on at least one surface of the current collector, and thepair of blades cuts the active material layer and does not cut thecurrent collector.

In a yet further aspect of the present disclosure, the pair of bladesforms a cut without cutting the current collector.

In a yet still further aspect of the present disclosure, the currentcollector is cut by tensile stress by rotation of the holding heads.

In a yet still further aspect of the present disclosure, the rectangularelectrode assembly comprises a current collector and an active materiallayer formed on at least one surface of the current collector, thecurrent collector has a cut surface by tensile stress, and the activematerial layer has a cut surface by shearing stress.

In a yet still further aspect of the present disclosure, the cuttingmeans cut the rectangular electrode assembly by reciprocating in a widthdirection of the rectangular electrode assembly, which is a directionroughly orthogonal to the circumferential direction of the drum.

In a yet still further aspect of the present disclosure, a movingsurface during forward movement and a moving surface during returnmovement in the reciprocation are different from each other.

In a yet still further aspect of the present disclosure, the cuttingmeans cut the rectangular electrode assembly by being moved forward inthe width direction of the rectangular electrode assembly, which is thedirection roughly orthogonal to the circumferential direction of thedrum, the holding head holding the cut rectangular electrode assembly ismoved in a direction of separating from the holding head holding therectangular electrode assembly, and the cutting means are moved back inthe width direction of the rectangular electrode assembly, which is thedirection roughly orthogonal to the circumferential direction of thedrum, after being moved in the direction of separating from therectangular electrode assembly.

In a yet still further aspect of the present disclosure, each blade ofthe pair of blades is a rotary round blade.

In a yet still further aspect of the present disclosure, each blade ofthe pair of blades is a rotary round blade with a flat portion formed atone part.

In a yet still further aspect of the present disclosure, the pair ofblades cuts the rectangular electrode assembly by round blade portionsfacing each other during forward movement in the reciprocation, and doesnot come into contact with the rectangular electrode assembly while theflat portions face each other during return movement.

A yet still further aspect of the present disclosure is a separatorcutting device comprising: a plurality of holding heads arranged in acircumferential direction of a drum and rotated around a drum centeraxis holding a belt-like separator; and cutting means provided in eachof the plurality of holding heads and configured to cut the belt-likeseparator in a predetermined width, the cutting means comprise a pair ofblades arranged in a thickness direction of the belt-like separator soas to hold the belt-like separator therebetween, and the cutting meanscut the belt-like separator by reciprocating in a width direction of thebelt-like separator, which is a direction roughly orthogonal to thecircumferential direction of the drum.

In a yet still further aspect of the present disclosure, a movingsurface during forward movement and a moving surface during returnmovement in the reciprocation are different from each other.

In a yet still further aspect of the present disclosure, the cuttingmeans cut the rectangular electrode assembly by being moved forward inthe width direction of the belt-like separator, which is the directionroughly orthogonal to the circumferential direction of the drum, theholding head holding the cut separator is moved in a direction ofseparating from the holding head holding the belt-like separator, andthe cutting means are moved back in the width direction of the belt-likeseparator, which is the direction roughly orthogonal to thecircumferential direction of the drum, after being moved in thedirection of separating from the belt-like separator.

In a yet still further aspect of the present disclosure, each blade ofthe pair of blades is a rotary round blade.

In a yet still further aspect of the present disclosure, each blade ofthe pair of blades is a rotary round blade with a flat portion formed atone part.

In a yet still further aspect of the present disclosure, the pair ofblades cuts the belt-like separator by round blade portions facing eachother during the forward movement in the reciprocation, and does notcome into contact with the belt-like separator while the flat portionsface each other during the return movement.

One aspect of the present disclosure makes it possible to efficientlycut a rectangular electrode assembly configuring a laminated electrodeassembly.

In addition, another aspect of the present disclosure further makes itpossible to suppress damages of a cut surface of the rectangularelectrode assembly.

BRIEF DESCRIPTION OF DRAWING

FIG. 1 is a conceptual configuration diagram of a manufacturing deviceof an embodiment.

FIG. 2 is a configuration perspective view of the manufacturing deviceof the embodiment.

FIG. 3 is an explanatory diagram illustrating a manufacturing method ofa 4-layer laminated body of the embodiment.

FIG. 4 is a configuration diagram of the 4-layer laminated body of theembodiment.

FIG. 5 is an explanatory diagram illustrating a manufacturing method ofa 3-layer laminated body of the embodiment.

FIG. 6 is a configuration diagram of the 3-layer laminated body of theembodiment.

FIG. 7 is a lamination explanatory diagram of the 3-layer laminated bodyand the 4-layer laminated body of the embodiment.

FIG. 8 is a cutting explanatory diagram of a separator of theembodiment.

FIG. 9 is a generation order explanatory diagram of the 3-layerlaminated body and the 4-layer laminated body of the embodiment.

FIG. 10 is a configuration diagram of a laminated electrode assembly ofthe embodiment.

FIG. 11 is a configuration perspective view of a positive electrodecutting head of the embodiment.

FIG. 12 is a cutting explanatory diagram of a positive electrode singleplate of a comparative example.

FIG. 13 is a cutting explanatory diagram (part 1) of the positiveelectrode single plate of the embodiment.

FIG. 14 is a cutting explanatory diagram (part 2) of the positiveelectrode single plate of the embodiment.

FIG. 15 is a reciprocation explanatory diagram of a round blade of theembodiment.

FIG. 16 is a top view and a side view of the positive electrode singleplate of the embodiment.

FIG. 17 is a cut surface explanatory diagram of the positive electrodesingle plate of the embodiment.

FIG. 18 is a cut surface explanatory diagram of the positive electrodesingle plate of the comparative example.

FIG. 19 is an explanatory diagram illustrating another blade shape ofthe embodiment.

FIG. 20 is a reciprocation explanatory diagram of another blade of theembodiment.

FIG. 21 is a supply explanatory diagram of the positive electrode singleplate of the embodiment.

FIG. 22 is a partially enlarged view of FIG. 21.

FIG. 23A is an explanatory diagram of a negative electrode heating drumand a bonding drum of the embodiment.

FIG. 23B is a perspective view of a pressurizing force adjustingmechanism of the embodiment.

FIG. 23C is a rear elevation of the pressurizing force adjustingmechanism of the embodiment.

FIG. 24 is a bonding explanatory diagram of a negative electrode plateof the comparative example.

FIG. 25 is a bonding explanatory diagram of a negative electrode plateof the embodiment.

FIG. 26 is a pressurizing range explanatory diagram for the time ofbonding the negative electrode plate of the embodiment.

FIG. 27 is a pressurizing range explanatory diagram for the time ofbonding a separator S2 of the embodiment.

FIG. 28 is a pressurizing range explanatory diagram for the time ofbonding a negative electrode plate of the embodiment.

FIG. 29 is a configuration perspective view of a laminating drum of theembodiment.

FIG. 30 is an operation explanatory diagram (part 1) of the laminatingdrum of the embodiment.

FIG. 31 is an operation explanatory diagram (part 2) of the laminatingdrum of the embodiment.

FIG. 32 is an operation explanatory diagram (part 3) of the laminatingdrum of the embodiment.

FIG. 33 is an operation explanatory diagram (part 4) of the laminatingdrum of the embodiment.

FIG. 34 is a configuration perspective view of a laminating head of theembodiment.

FIG. 35 is a graphical representation illustrating a position change ofthe laminating head of the embodiment.

FIG. 36 is a configuration perspective view of a laminating stage of theembodiment.

FIG. 37 is a diagram illustrating a claw arrangement of the laminatingstage of the embodiment.

FIG. 38 is a claw operation explanatory diagram of the laminating stageof the embodiment.

FIG. 39 is a plan view illustrating another claw arrangement of thelaminating stage of the embodiment.

FIG. 40 is a linked operation explanatory diagram (part 1) of thelaminating head and claws of the embodiment.

FIG. 41 is a linked operation explanatory diagram (part 2) of thelaminating head and the claws of the embodiment.

FIG. 42 is a linked operation explanatory diagram (part 3) of thelaminating head and the claws of the embodiment.

FIG. 43 is a linked operation explanatory diagram (part 4) of thelaminating head and the claws of the embodiment.

FIG. 44 is a linked operation explanatory diagram (part 5) of thelaminating head and the claws of the embodiment.

FIG. 45 is a conceptual configuration diagram of a modification 1.

FIG. 46 is a lamination explanatory diagram of the modification 1.

FIG. 47 is another lamination explanatory diagram of the modification 1.

FIG. 48 is a conceptual configuration diagram of a modification 2.

FIG. 49 is another conceptual configuration diagram of the modification2.

FIG. 50 is a conceptual configuration diagram of a modification 3.

FIG. 51 is a conceptual configuration diagram of a modification 4.

DESCRIPTION OF EMBODIMENTS

Hereinafter, a laminated electrode assembly manufacturing device andmanufacturing method relating to one aspect of the present disclosurewill be described. However, the embodiment described hereinafter is anexample and the present disclosure is not limited thereto.

FIG. 1 illustrates a conceptual diagram of a laminated electrodeassembly manufacturing device in the present embodiment. Themanufacturing device of the embodiment is a continuous drum typemanufacturing device for which a plurality of drums are combined, andcomprises a negative electrode cutting drum 10, a negative electrodeheating drum 12, a positive electrode cutting drum 14, a positiveelectrode heating drum 16, a bonding drum 18, a separator cutting drum20 and a laminating drum 22.

The negative electrode cutting drum 10 is a first electrode cuttingdrum, has a first radius, and is rotated around a central axis at afirst angular velocity. To the negative electrode cutting drum 10, abelt-like negative electrode single plate N is supplied as a firstelectrode single plate. The negative electrode single plate N is anegative electrode. The negative electrode single plate N is configuredby a negative electrode current collector, and a negative electrodeactive material layer formed on the negative electrode currentcollector. The negative electrode active material layer may be formed onone surface of the negative electrode current collector, or may beformed on both surfaces. In the description below, it is assumed thatthe negative electrode active material layer is formed on both surfacesof the negative electrode current collector. The negative electrodeactive material layer includes a negative electrode active material anda binding material.

For both of the negative electrode current collector and the negativeelectrode active material layer, known materials can be used, and areexemplified as follows for a lithium ion secondary battery.

As the negative electrode current collector, foil of a metal which isstable in a potential range of the negative electrode, and a film forwhich the metal is arranged on a surface layer or the like can be used.As the negative electrode current collector, a porous body such as amesh body, a punching sheet or an expand metal of the metal may be used.As the material of the negative electrode current collector, copper,copper alloy, aluminum, aluminum alloy, stainless steel, nickel or thelike can be used. A thickness of the negative electrode currentcollector is preferably 3 μm or more and 50 μm or less for example, fromviewpoints of a current collection property, mechanical strength or thelike. The negative electrode single plate N can be manufactured byapplying negative electrode mixture slurry including the negativeelectrode active material, the binding material and a dispersion mediumonto the negative electrode current collector, drying a coating film,then performing rolling and forming the negative electrode activematerial layer on one surface or both surfaces of the negative electrodecurrent collector for example. The negative electrode active materiallayer may include an arbitrary component such as a conductive agent asneeded. The thickness of the negative electrode active material layer isnot limited in particular, and is 10 μm or more and 100 μm or less forexample.

In the case of the lithium ion secondary battery, the negative electrodeactive material is not limited in particular as long as it is a materialcapable of occluding/releasing lithium ions. The material configuringthe negative electrode active material may be a non-carbon-basedmaterial, may be a carbon material, or may be the combination thereof.

Examples of the non-carbon-based material are lithium metal, alloyincluding a lithium element and a metal compound such as metal oxide,metal sulfide or metal nitride containing lithium. Examples of the alloycontaining the lithium element are lithium aluminum alloy, lithium tinalloy, lithium lead alloy and lithium silicon alloy. An example of themetal oxide containing the lithium is the metal oxide containing thelithium and titanium, tantalum, niobium or the like, and lithiumtitanate (Li₄Ti₅O₁₂ or the like) is preferable. Examples of the carbonmaterial used as the negative electrode active material are graphite andhard carbon. Among them, the graphite is preferable since a capacity ishigh and an irreversible capacity is small. The graphite is a generalterm of the carbon material having a graphite structure, and includesnatural graphite, artificial graphite, expanded graphite, graphitizedmesophase carbon particles or the like. In the case of using thegraphite as the negative electrode active material, it is preferable tocoat the surface of the negative electrode active material layer with acoating film in order to lower activity to reductive decomposition of anaqueous electrolyte. For the negative electrode active materials, onekind may be used alone, or two or more kinds may be used together. Asthe binding material included in the negative electrode active materiallayer, a fluorine-based polymer, a rubber-based polymer or the like maybe used, and a styrene-butadiene copolymer (SBR) or the modified productor the like may be used.

The negative electrode cutting drum 10 comprises a plurality ofelectrode cutting heads arranged in a circumferential direction of thedrum. The plurality of electrode cutting heads comprise an outerperipheral surface for sucking and holding the negative electrode singleplate N, and cutting means. The cutting means are, for example, a blademoved in a direction roughly orthogonal to the circumferential directionof the outer peripheral surface. The supplied negative electrode singleplate N is sucked and held on the outer peripheral surface and rotated.The electrode cutting heads suck and hold the negative electrode singleplate N so that they are also referred to as holding heads. A gap isformed between the plurality of electrode cutting heads, and by movementof the blade loaded on the electrode cutting head in the directionroughly orthogonal to the circumferential direction at the gap, thenegative electrode single plate N sucked and held on the outerperipheral surface is cut to have a predetermined width (first width) bythe blade.

The plurality of electrode cutting heads are each rotated around acommon central axis of the negative electrode cutting drum 10, and theindividual electrode cutting head is driven by a motor in thecircumferential direction of the drum independent of the other electrodecutting heads. For example, when the two electrode cutting headsadjacent in the circumferential direction are an electrode cutting head‘a’ and an electrode cutting head ‘b’, the electrode cutting head ‘a’and the electrode cutting head ‘b’ are rotated around the common centralaxis of the drum at a fixed speed, and a mutual relative speed ischanged for every predetermined section on a circumference of thenegative electrode cutting drum 10. For example, the electrode cuttinghead ‘a’ and the electrode cutting head ‘b’ are both rotated at thefixed speed and the relative speed is 0 at a certain timing, but theelectrode cutting head ‘a’ is accelerated in a direction of separatingfrom the following electrode cutting head ‘b’ and the relative speedbecomes finite at a different timing. By such independent drive of theelectrode cutting head, a cutting position of the negative electrodesingle plate N by the blade loaded on the electrode cutting head can beadjusted, and a position of a negative electrode plate generated bycutting can be adjusted. A moving speed of the electrode cutting headcan be achieved by using a motor or the like corresponding to eachelectrode cutting head.

The negative electrode cutting drum 10 may comprise various kinds ofcameras, and the position of the negative electrode single plate Nbefore cutting may be monitored and also the positions of the pluralityof negative electrode plates generated by cutting may be monitored bythe cameras. The negative electrode cutting drum 10 sucks, holds,rotationally conveys the supplied negative electrode single plate N,cuts the negative electrode single plate N at a position 11 in FIG. 1,and generates the negative electrode plate. The electrode cutting headrotated while sucking and holding the negative electrode single plate Nis rotated while sucking and holding the negative electrode single plateN to the position 11, and cuts the negative electrode single plate N bythe loaded blade at a point of time of reaching the position 11. Thenegative electrode plate of the first width generated by cutting isrotationally conveyed while being kept sucked and held on the outerperipheral surface of each electrode cutting head.

The negative electrode heating drum 12 is a first electrode heatingdrum, and is arranged adjacently to the negative electrode cutting drum10 so as to be close to the negative electrode cutting drum 10. Thenegative electrode heating drum 12 has a second radius, and is rotatedaround the central axis at a second angular velocity. The second radiusof the negative electrode heating drum 12 may be same as the firstradius of the negative electrode cutting drum 10 or may be different.The second angular velocity of the negative electrode heating drum 12 isdifferent from the first angular velocity of the negative electrodecutting drum 10. Specifically, the second angular velocity of thenegative electrode heating drum 12 is set such that the linear velocityis roughly same as the linear velocity of the bonding drum 18 to bedescribed later. As one example, the second radius and the first radiusare the same, and setting is performed to be the second angularvelocity>the first angular velocity. In this case, the linear velocitiesof the negative electrode cutting drum 10 and the negative electrodeheating drum 12 are different, and are the linear velocity of thenegative electrode heating drum 12>the linear velocity of the negativeelectrode cutting drum 10. Accordingly, the electrode cutting head ofthe negative electrode cutting drum 10 is temporarily accelerated to beroughly same as the linear velocity of the negative electrode heatingdrum 12 in front of a position close to the negative electrode heatingdrum 12, and turns the relative speed with the negative electrodeheating drum 12 to roughly zero. The electrode cutting head of thenegative electrode cutting drum 10 discharges the sucked and heldnegative electrode plate to a side of the negative electrode heatingdrum 12 at the timing when the relative speed becomes roughly zero. Theelectrode cutting head of the negative electrode cutting drum 10 isswitched to the speed before acceleration after discharging the suckedand held negative electrode plate.

The negative electrode heating drum 12 sucks and holds the negativeelectrode plate discharged from the negative electrode cutting drum 10,and heats (preliminarily heats) the negative electrode plate by abuilt-in heater. The figure illustrates that the negative electrodeplate is heated at a position 13. The heating (preliminary heating)process is for heat-bonding a separator and the negative electrode platein a subsequent bonding process. A location of heating by the negativeelectrode heating drum 12 is not limited to a specific position (forexample, the position 13). The negative electrode heating drum 12 may bein a heated state at all times while the drum is rotated.

The positive electrode cutting drum 14 is a second electrode cuttingdrum, has a third radius, and is rotated around the central axis at athird angular velocity. To the positive electrode cutting drum 14, abelt-like positive electrode single plate P is supplied as a secondelectrode single plate. The positive electrode single plate P is arectangular electrode assembly. The positive electrode single plate P isconfigured by a positive electrode current collector, and a positiveelectrode active material layer formed on the positive electrode currentcollector. The positive electrode active material layer may be formed onone surface of the positive electrode current collector, or may beformed on both surfaces. In the description below, it is assumed thatthe positive electrode active material layer is formed on both surfacesof the positive electrode current collector. The positive electrodeactive material layer includes a positive electrode active material anda binding material.

For both of the positive electrode current collector and the positiveelectrode active material layer, known materials can be used, and areexemplified as follows.

As the positive electrode current collector, foil of a metal which isstable in a potential range of the positive electrode, and a film forwhich the metal is arranged on a surface layer or the like can be used.As the positive electrode current collector, a porous body such as amesh body, a punching sheet or an expand metal of the metal may be used.As the material of the positive electrode current collector, thestainless steel, the aluminum, the aluminum alloy, titanium or the likecan be used. A thickness of the positive electrode current collector ispreferably 3 μm or more and 50 μm or less for example, from theviewpoints of the current collection property, the mechanical strengthor the like. The positive electrode single plate can be obtained byforming the positive electrode active material layer on the positiveelectrode current collector by applying/drying positive electrodemixture slurry including the positive electrode active material, theconductive material, the binding material or the like on the positiveelectrode current collector, and rolling the positive electrode activematerial layer, for example. The thickness of the positive electrodeactive material layer is not limited in particular, and is 10 μm or moreand 100 μm or less for example.

The positive electrode active material is lithium transition metal oxidecontaining lithium (Li) and a transition metal element such as cobalt(Co), manganese (Mn) and nickel (Ni). An example of the conductivematerial included in the positive electrode active material layer iscarbon powder such as carbon black, acetylene black, Ketjen black,graphite or the like. For them, one kind may be used alone or two ormore kinds may be combined and used. Examples of the binding materialincluded in the positive electrode active material layer are thefluorine-based polymer, the rubber-based polymer and the like. Examplesof the fluorine-based polymer are polytetrafluoroethylene (PTFE),polyvinylidene fluoride (PVDF) and the modified product or the like, andexamples of the rubber-based polymer are an ethylene-propylene-isoprenecopolymer and an ethylene-propylene-butadiene copolymer. For them, onekind may be used alone or two or more kinds may be combined and used.

The positive electrode cutting drum 14 comprises a plurality ofelectrode cutting heads arranged in the circumferential direction of thedrum. The electrode cutting head comprises an outer peripheral surfacefor sucking and holding the positive electrode single plate P, andcutting means. The cutting means are, for example, a blade moved in thedirection roughly orthogonal to the circumferential direction of theouter peripheral surface. The supplied positive electrode single plate Pis sucked and held on the outer peripheral surface and rotated. Theelectrode cutting heads suck and hold the positive electrode singleplate P so that they are also referred to as holding heads. A gap isformed in the circumferential direction between the plurality ofelectrode cutting heads, and by the movement of the blade loaded on theelectrode cutting head in the direction roughly orthogonal to thecircumferential direction at the gap, the positive electrode singleplate P sucked and held on the outer peripheral surface is cut to have apredetermined width (second width) by the blade. Similarly to theelectrode cutting heads of the negative electrode cutting drum 10, theplurality of electrode cutting heads are each rotated around the commoncentral axis of the positive electrode cutting drum 14, and theindividual electrode cutting head is driven by a motor in thecircumferential direction of the drum independent of the other electrodecutting heads. For example, when the two electrode cutting headsadjacent in the circumferential direction are an electrode cutting head‘a’ and an electrode cutting head ‘b’, the electrode cutting head ‘a’and the electrode cutting head ‘b’ are rotated around the common centralaxis of the drum at the fixed speed, and the mutual relative speed ischanged for every predetermined section on the circumference of thepositive electrode cutting drum 14. For example, the electrode cuttinghead ‘a’ and the electrode cutting head ‘b’ are both rotated at thefixed speed and the relative speed is 0 at a certain timing, but theelectrode cutting head ‘a’ is accelerated in the direction of separatingfrom the following electrode cutting head ‘b’ and the relative speedbecomes finite at a different timing. By such independent drive of theelectrode cutting head, the cutting position of the positive electrodesingle plate P by a round blade loaded on the electrode cutting head canbe adjusted, and the position of a negative electrode plate generated bycutting can be adjusted. The moving speed of the electrode cutting headcan be achieved by using the motor or the like corresponding to eachelectrode cutting head.

The positive electrode cutting drum 14 may comprise various kinds ofcameras, and the position of the positive electrode single plate Pbefore cutting may be monitored and also the positions of the pluralityof positive electrode plates generated by cutting may be monitored bythe cameras. The positive electrode cutting drum 14 sucks, holds androtationally conveys the supplied positive electrode single plate P,cuts the positive electrode single plate P at a position 15 in FIG. 1,and generates the positive electrode plate. The electrode cutting headrotated while sucking and holding the positive electrode single plate Pis rotated while sucking and holding the positive electrode single plateP to the position 15, and cuts the positive electrode single plate P bythe loaded blade at the point of time of reaching the position 15. Thepositive electrode plate generated by cutting is rotationally conveyedwhile being kept sucked and held on the outer peripheral surface of eachelectrode cutting head.

The positive electrode heating drum 16 is a second electrode heatingdrum, and is arranged adjacently to the positive electrode cutting drum14 so as to be close to the positive electrode cutting drum 14. Thepositive electrode heating drum 16 has a fourth radius, and is rotatedaround the central axis at a fourth angular velocity. The fourth radiusof the positive electrode heating drum 16 may be the same as the thirdradius of the positive electrode cutting drum 14 or may be different.The fourth angular velocity of the positive electrode heating drum 16 isdifferent from the third angular velocity of the positive electrodecutting drum 14. Specifically, the fourth angular velocity of thepositive electrode heating drum 16 is set such that the linear velocityis roughly the same as the linear velocity of the bonding drum 18 to bedescribed later. As one example, the fourth radius and the third radiusare the same, and setting is performed to be the fourth angularvelocity>the third angular velocity. In this case, the linear velocitiesof the positive electrode cutting drum 14 and the positive electrodeheating drum 16 are different, and are the linear velocity of thepositive electrode heating drum 16>the linear velocity of the positiveelectrode cutting drum 14. Accordingly, the electrode cutting head ofthe positive electrode cutting drum 14 is temporarily accelerated to beroughly the same as the linear velocity of the positive electrodeheating drum 16 in front of the position close to the positive electrodeheating drum 16, and turns the relative speed with the positiveelectrode heating drum 16 to roughly zero. The electrode cutting head ofthe positive electrode cutting drum 14 discharges the sucked and heldpositive electrode plate to the side of the positive electrode heatingdrum 16 at the timing when the relative speed becomes roughly zero. Theelectrode cutting head of the positive electrode cutting drum 14 isswitched to a rotating speed before the acceleration after dischargingthe sucked and held positive electrode plate.

The positive electrode heating drum 16 sucks and holds the positiveelectrode plate discharged from the positive electrode cutting drum 14,and heats (preliminarily heats) the positive electrode plate by abuilt-in heater. The figure illustrates that the positive electrodeplate is heated at a position 17. The heating (preliminary heating)process is for heat-bonding a separator and the positive electrode platein the subsequent bonding process. The location of heating by thepositive electrode heating drum 16 is not limited to a specific position(for example, the position 17). The positive electrode heating drum 16may be in the heated state at all times while the drum is rotated.

The bonding drum 18 is arranged between the negative electrode heatingdrum 12 and the positive electrode heating drum 16 so as to be close toboth of the negative electrode heating drum 12 and the positiveelectrode heating drum 16. The bonding drum 18 has a fifth radius, andis rotated around the central axis at a fifth angular velocity. To thebonding drum 18, a belt-like separator S1 is supplied as a firstseparator single plate, and a belt-like separator S2 is supplied as asecond separator single plate. Further, the negative electrode plateheated by the negative electrode heating drum 12 is supplied and thepositive electrode plate heated by the positive electrode heating drum16 is supplied.

For the negative electrode plate, the linear velocity of the negativeelectrode heating drum 12 and the linear velocity of the bonding drum 18are roughly the same, and the heated negative electrode plate sucked andheld by the negative electrode heating drum 12 is discharged to the sideof the bonding drum 18 at the position close to the bonding drum 18. Inaddition, also for the positive electrode plate, the linear velocity ofthe positive electrode heating drum 16 and the linear velocity of thebonding drum 18 are roughly the same, and the heated positive electrodeplate sucked and held by the positive electrode heating drum 16 isdischarged to the side of the bonding drum 18 at the position close tothe bonding drum 18.

Note that, since the linear velocity of the negative electrode heatingdrum 12 and the linear velocity of the bonding drum 18 are roughly thesame, the linear velocity of the electrode cutting head of the negativeelectrode cutting drum 10 in front of the position close to the negativeelectrode heating drum 12 is roughly the same as the linear velocity ofthe bonding drum 18. In addition, since the linear velocity of thepositive electrode heating drum 16 and the linear velocity of thebonding drum 18 are roughly the same, the linear velocity of theelectrode cutting head of the positive electrode cutting drum 14 infront of the position close to the positive electrode heating drum 16 isroughly the same as the linear velocity of the bonding drum 18.Accordingly, the electrode cutting head discharges the sucked and heldnegative electrode plate or positive electrode plate at the timing whenthe linear velocity becomes roughly the same with the bonding drum 1.

By the bonding drum 18, the belt-like separator S1 is sucked and held ata predetermined position. Thereafter, at the position close to thenegative electrode heating drum 12 positioned on a downstream side of arotation direction, the heated negative electrode plate discharged fromthe negative electrode heating drum 12 is arranged on the separator S1.Then, the belt-like separator S2 is arranged on the negative electrodeplate at a predetermined position on the further downstream side of therotation direction. Thereafter, the separator S1, the negative electrodeplate and the separator S2 are bonded by being pressurized by athermocompression bonding roller 19, the heated positive electrode platedischarged from the positive electrode heating drum 16 is arranged inthe separator S2 at the position near the positive electrode heatingdrum 16 positioned on the further downstream side of the rotationdirection, and the positive electrode plate is bonded by pressing forceof the positive electrode heating drum 16. On the surfaces of theseparator S1 and the separator S2, a heat bonding layer whereadhesiveness is not expressed at a room temperature but the adhesivenessis expressed by heating is formed. The heat bonding layer is athermoplastic layer containing a thermoplastic polymer for example, andbonds the belt-like separator S1 and the negative electrode plate, thenegative electrode plate and the belt-like separator S2, and thebelt-like separator S2 and the positive electrode plate by utilizingplastic deformation of the thermoplastic polymer by heating. In such amanner, a 4-layer laminated body of

the belt-like separator S1/the negative electrode plate/the belt-likeseparator S2/the positive electrode plate

is generated at the bonding drum 18. The 4-layer laminated body isconveyed from the bonding drum 18 to the separator cutting drum 20.

On the other hand, at an interval of every fixed number of pieces, thepositive electrode plate is not supplied from the positive electrodecutting drum 14 and the positive electrode plate is not supplied fromthe positive electrode heating drum 16 either. Therefore, the positiveelectrode plate is not supplied to the bonding drum 18 at the intervalof every fixed number of pieces, and a 3-layer laminated body of

the belt-like separator S1/the negative electrode plate/the belt-likeseparator S2 is generated at the bonding drum 18. The 3-layer laminatedbody is conveyed from the bonding drum 18 to the separator cutting drum20 similarly to the 4-layer laminated body.

The separator cutting drum 20 has a sixth radius, and is rotated aroundthe central axis at a sixth angular velocity. The separator cutting drum20 comprises a plurality of separator cutting heads arranged in thecircumferential direction of the drum. The separator cutting headcomprises an outer peripheral surface for sucking and holding the4-layer laminated body and the 3-layer laminated body, and cuttingmeans. The cutting means are, for example, a blade moved in thedirection roughly orthogonal to the circumferential direction of theouter peripheral surface. The conveyed 4-layer laminated body and3-layer laminated body are sucked and held on the outer peripheralsurface and rotated. The separator cutting heads suck and hold the4-layer laminated body and the 3-layer laminated body so that they arealso referred to as holding heads. A gap is formed in thecircumferential direction between the plurality of separator cuttingheads, and by the movement of the blade loaded on the separator cuttinghead in the direction roughly orthogonal to the circumferentialdirection at the gap, the 4-layer laminated body and the 3-layerlaminated body sucked and held on the outer peripheral surface are cutto have a predetermined width (third width) by the blade. Specifically,the belt-like separator S1 and the belt-like separator S2 are cutbetween the adjacent negative electrode plates arranged at apredetermined interval of the 4-layer laminated body of

the belt-like separator S1/the negative electrode plate/the belt-likeseparator S2/the positive electrode plate, or between the adjacentnegative electrode plates arranged at the predetermined interval of the3-layer laminated body of

the belt-like separator S1/the negative electrode plate/the belt-likeseparator S2, or between the adjacent negative electrode plates arrangedat the predetermined interval of the 4-layer laminated body and the3-layer laminated body. The figure illustrates that cutting is performedat a position 21.

The laminating drum 22 has a seventh radius, and is rotated around thecentral axis at a seventh angular velocity. The linear velocity of thelaminating drum is adjusted to be roughly the same as the linearvelocity of the separator cutting drum 20. The laminating drum 22comprises a plurality of laminating heads arranged in thecircumferential direction of the drum. The laminating head comprises anouter peripheral surface for sucking and holding the cut 4-layerlaminated body and 3-layer laminated body. The plurality of laminatingheads are each rotated around the common central axis of the laminatingdrum 22, and the individual laminating head is driven by a cam in thecircumferential direction of the drum independent of the otherlaminating heads. For example, when the two laminating heads adjacent inthe circumferential direction are a laminating head ‘a’ and a laminatinghead ‘b’, the laminating head ‘a’ and the laminating head ‘b’ arerotated around the common central axis of the drum at the fixed speed,and the mutual relative speed is changed for every predetermined sectionon the circumference of the laminating drum 22. For example, thelaminating head ‘a’ and the laminating head ‘b’ are both rotated at thefixed speed so that the relative speed is 0 at a certain timing, but thelaminating head ‘a’ is accelerated in the direction of separating fromthe following laminating head ‘b’ and the relative speed becomes finiteat a different timing. By such independent drive of the laminating head,a stop state at a laminating position of a specific laminating head ismade possible while maintaining rotation at the fixed angular velocityas the entire laminating drum 22, and the cut 4-layer laminated body and3-layer laminated body sucked and held on the outer peripheral surfacecan be discharged and arranged on a laminating stage 24 in the stopstate.

The laminating stage 24 is arranged right under the laminating drum 22.On the laminating stage 24, the cut 4-layer laminated body and 3-layerlaminated body discharged from the laminating drum 22 are successivelylaminated and a laminated electrode assembly is formed. The laminatingstage 24 is drivable in two axial (X axis and Y axis) directionorthogonal to each other, an inclination angle (θ) on an X-Y plane isadjustable, and thus positioning is performed by adjusting the position(XY position) and the inclination angle (θ) of the cut 4-layer laminatedbody and 3-layer laminated body discharged from the laminating drum 22,the cut 4-layer laminated body and 3-layer laminated body aresuccessively laminated, and the laminated electrode assembly ismanufactured. The laminating stage 24 comprises claws at four corners,and the laminated 4-layer laminated body and 3-layer laminated body arepressed and fixed by the claws. The laminated 3-layer laminated body and4-layer laminated body are pressurized and/or heated, and bonded to eachother.

An outline of a manufacturing process of the laminated electrodeassembly is put in order as follows.

(1) The negative electrode plate is generated by cutting negativeelectrode single plate on the drum.

(2) The negative electrode plate is heated on the drum.

(3) The positive electrode plate is generated by cutting the positiveelectrode single plate on the drum.

(4) The positive electrode plate is heated on the drum.

(5) The belt-like separator and the negative electrode plate are bondedon the drum, the belt-like separator is bonded further on the drum, andthe positive electrode plate is bonded further on the drum.

(6) The 3-layer laminated body and the 4-layer laminated body aregenerated by cutting the belt-like separator on the drum.

(7) The 3-layer laminated body and the 4-layer laminated body arelaminated by the drum.

(8) The laminated 3-layer laminated body and 4-layer laminated body arepressurized and/or heated to be bonded to each other.

By executing the individual processes of cutting, heating, bonding andlaminating on the drums in such a manner, high-speed and continuousprocessing is made possible.

FIG. 2 illustrates a specific configuration perspective view of themanufacturing device in the embodiment.

In the order from left in the figure, the negative electrode cuttingdrum 10, the negative electrode heating drum 12, the bonding drum 18,the positive electrode heating drum 16 and the positive electrodecutting drum 14 are closely arranged. The negative electrode cuttingdrum 10 and the negative electrode heating drum 12 are closely arranged,the negative electrode heating drum 12 and the bonding drum 18 areclosely arranged, the positive electrode cutting drum 14 and thepositive electrode heating drum 16 are closely arranged, and thepositive electrode heating drum 16 and the bonding drum 18 are closelyarranged. The negative electrode cutting drum 10, the negative electrodeheating drum 12, the bonding drum 18, the positive electrode heatingdrum 16 and the positive electrode cutting drum 14 are each rotatedaround the central axis, and their central axes are approximatelyparallel to each other.

To the negative electrode cutting drum 10, the belt-like negativeelectrode single plate N the tension of which is adjusted by a tensionroller is supplied. The negative electrode cutting drum 10 comprises theplurality of cutting heads rotated around the central axis, 12 electrodecutting heads arranged in the circumferential direction for example, andthe belt-like negative electrode single plate N is sucked and held onthe outer peripheral surface of the electrode cutting heads and rotatedtogether with the electrode cutting heads.

The plurality of electrode cutting heads are each provided with theblade moved in the direction roughly orthogonal to the circumferentialdirection, that is a width direction of the negative electrode cuttingdrum, and the blade is moved in the width direction of the drum in afixed range of the rotation direction and cuts the negative electrodesingle plate N. After cutting the negative electrode single plate N, theelectrode cutting head is moved in the circumferential directionindependent of the other electrode cutting heads, the gap between thenegative electrode plates is adjusted, and the relative speed is turnedto roughly 0 at the position close to the negative electrode heatingdrum 12.

The negative electrode plate sucked and held by the electrode cuttinghead of the negative electrode cutting drum 10 is supplied to thenegative electrode heating drum 12 at the position close to the negativeelectrode heating drum 12. Specifically, on the outer peripheral surfaceof the electrode cutting head (holding head), suction holes for suckingand holding the negative electrode plate are formed, and a grooveextending in the circumferential direction is formed. To the grooveformed on the holding head, supply means to be engaged with the grooveto separate the negative electrode plate which is the electrode assemblyfrom a suction surface of the holding head and supply it to the drum ofa next stage are arranged between the holding head and the drum of thenext stage. As the supply means, for example, a belt conveyor isinserted into the groove at the position close to the negative electrodeheating drum 12, the negative electrode plate sucked and held by theelectrode cutting head is made to get on the belt conveyor, and thenegative electrode plate is supplied to the side of the negativeelectrode heating drum 12 via the belt conveyor. The belt conveyor willbe further described later. The negative electrode cutting drum 10rotationally conveys the negative electrode plate at the predeterminedinterval.

To the negative electrode heating drum 12, the negative electrode platescut by the negative electrode cutting drum 10 are successively supplied.The negative electrode heating drum 12 is rotated at the roughly samelinear velocity as the bonding drum 18, heats the negative electrodeplates and rotationally conveys the heated negative electrode plates tothe position close to the bonding drum 18.

In addition, to the positive electrode cutting drum 14, the belt-likepositive electrode single plate P the tension of which is adjusted by aplurality of tension rollers is supplied. The positive electrode cuttingdrum 14 comprises the plurality of cutting heads rotated around thecentral axis, 12 electrode cutting heads arranged in the circumferentialdirection for example, and the belt-like positive electrode single plateP is sucked and held on the outer peripheral surface of the electrodecutting heads and rotated together with the electrode cutting heads.

The plurality of electrode cutting heads are each provided with theblade moved in the direction roughly orthogonal to the circumferentialdirection, that is the width direction of the positive electrode cuttingdrum, and the blade is moved in the width direction of the drum in thefixed range of the rotation direction and cuts the positive electrodesingle plate P. After cutting the positive electrode single plate P, theelectrode cutting head is moved in the circumferential directionindependent of the other electrode cutting heads, the gap between thepositive electrode plates is adjusted, and the relative speed is turnedto roughly 0 at the position close to the positive electrode heatingdrum 16.

The positive electrode plate sucked and held by the electrode cuttinghead of the positive electrode cutting drum 14 is supplied to thepositive electrode heating drum 16 at the position close to the positiveelectrode heating drum 16. Specifically, on the outer peripheral surfaceof the electrode cutting head (holding head), suction holes for suckingand holding the positive electrode plate are formed, and a grooveextending in the circumferential direction is formed. To the grooveformed on the holding head, supply means to be engaged with the grooveto separate the positive electrode plate which is the electrode assemblyfrom the suction surface of the holding head and supply it to the drumof the next stage are arranged between the holding head and the drum ofthe next stage. As the supply means, for example, a belt conveyor isinserted into the groove at the position close to the positive electrodeheating drum 16, the positive electrode plate sucked and held by theelectrode cutting head is made to get on the belt conveyor, and thepositive electrode plate is supplied to the side of the positiveelectrode heating drum 16 via the belt conveyor.

The positive electrode cutting drum 14 rotationally conveys the positiveelectrode plate at the predetermined interval.

To the positive electrode heating drum 16, the positive electrode platescut by the positive electrode cutting drum 14 are successively supplied.The positive electrode heating drum 16 is rotated at the roughly samelinear velocity as the bonding drum 18, heats the positive electrodeplates and rotationally conveys the heated positive electrode plates tothe position close to the bonding drum 18.

To the bonding drum 18, the belt-like separators S1 and S2 the tensionof which is adjusted by the plurality of tension rollers are supplied.In addition, the heated negative electrode plates are supplied at theposition close to the negative electrode heating drum 12, and the heatedpositive electrode plates are supplied at the position close to thepositive electrode heating drum 16. The bonding drum 18 is rotated to bein the same direction as the linear velocity of the negative electrodeheating drum 12 and the linear velocity of the positive electrodeheating drum 16. In the order from an upstream side to the downstreamside of the rotation direction of the bonding drum 18, a supply positionof the separator S1, a supply position of the negative electrode plate,a supply position of the separator S2 and a supply position of thepositive electrode plate are arranged. Between the supply position ofthe separator S2 and the supply position of the positive electrodeplate, the thermocompression bonding roller 19 is arranged.

The bonding drum 18 sucks and holds the belt-like separator S1 on theouter peripheral surface and rotationally conveys the separator S1.Then, at the position close to the negative electrode heating drum 12,the heated negative electrode plates are arranged on the separator S1 atthe predetermined interval and pressurized by an inter-drum pressure.The bonding drum 18 holds and rotationally conveys the negativeelectrode plates arranged at the predetermined interval on the separatorS1, the belt-like separator S2 is arranged on the negative electrodeplates at the supply position of the separator S2, and the 3-layerlaminated body of the separator S1/the negative electrode plate/theseparator S2 is pressure-bonded by the pressing force by thethermocompression bonding roller 19.

The 3-layer laminated body thermocompression-bonded by thethermocompression bonding roller 19 is rotationally conveyed further tothe position close to the positive electrode heating drum 16, and thepositive electrode plates are arranged at the predetermined interval onthe separator S2 at the position close to the positive electrode heatingdrum 16 and pressurized by the inter-drum pressure. The positiveelectrode plates are thermocompression-bonded to the separator S2 by theinter-drum pressure. In addition, the rotation of the positive electrodecutting drum 14 and the positive electrode heating drum 16 is stopped atthe interval of every fixed number of pieces, and the supply of thepositive electrode plates from the positive electrode heating drum 16 tothe bonding drum 18 is stopped. Thus, the positive electrode plate isnot arranged on the separator S2 and the 3-layer laminated body is leftas it is. The 3-layer laminated body formed of the belt-like separatorS1/the negative electrode plate/the belt-like separator S2 and the4-layer laminated body formed of the belt-like separator S1/the negativeelectrode plate/the belt-like separator S2/the positive electrode plateare conveyed to the separator cutting drum 20 via the plurality oftension rollers. Note that, instead of stopping the rotation of thepositive electrode cutting drum 14 and the positive electrode heatingdrum 16 at the timing of obtaining the 3-layer laminated body, the3-layer laminated body may be created and prepared separately and the3-layer laminated body may be introduced by a route different from anintroducing route of the 4-layer laminated body.

While the 3-layer laminated body and the 4-layer laminated body arethermocompression-bonded by the inter-drum pressure of the negativeelectrode heating drum 12 and the bonding drum 18, the inter-drumpressure of the positive electrode heating drum 16 and the bonding drum18 and the pressing force by the thermocompression bonding roller 19,when an end of the negative electrode plate cut by the negativeelectrode cutting drum 10 and an end of the positive electrode plate cutby the positive electrode cutting drum 14 are pressed by the drum or theroller, the end of the negative electrode plate and the end of thepositive electrode plate may be damaged. Therefore, by temporarilymitigating pressing by the inter-drum pressure and the thermocompressionbonding roller 19 at the end of the negative electrode plate cut by thenegative electrode cutting drum 10 and the end of the positive electrodeplate cut by the positive electrode cutting drum 14, damages areprevented. By mitigating the pressing at not only the end of thenegative electrode plate cut by the negative electrode cutting drum 10and the end of the positive electrode plate cut by the positiveelectrode cutting drum 14 but also the ends on four sides of thenegative electrode plate and the ends on four sides of the positiveelectrode plate, the damages of the negative electrode plate and thepositive electrode plate can be suppressed. That is, it is furtherpreferable to bond only the inside of the negative electrode plate andthe inside of the positive electrode plate with the separator forsuppressing the damages of the negative electrode plate and the positiveelectrode plate.

The separator cutting drum 20 may be arranged separately from thenegative electrode cutting drum 10, the negative electrode heating drum12, the bonding drum 18, the positive electrode heating drum 16 and thepositive electrode cutting drum 14 which are a group of drums.

The separator cutting drum 20 sucks and holds the 3-layer laminated bodyand the 4-layer laminated body supplied via the tension rollers on theouter peripheral surface, and cuts the belt-like separators S1 and S2 ofthe 3-layer laminated body and the 4-layer laminated body by a pluralityof separator cutting head structures similar to the negative electrodecutting drum 10. The cut 3-layer laminated body and 4-layer laminatedbody are rotationally conveyed to the position close to the laminatingdrum 22 while being kept sucked and held by the separator cutting heads.On the outer peripheral surface of the separator cutting head, suctionholes for sucking and holding the 3-layer laminated body and the 4-layerlaminated body are formed.

The separator cutting drum 20 rotationally conveys the 3-layer laminatedbody or the 4-layer laminated body at the predetermined interval.

The laminating drum 22 is arranged closely to the separator cutting drum20, and is rotated roughly the same as the linear velocity of theseparator cutting drum 20. The laminating drum 22 is configured by theplurality of laminating heads rotated around a drum rotation center. Forthe laminating head, a longitudinal section shape is roughly T-shaped,suction holes for sucking and holding the 3-layer laminated body and the4-layer laminated body are formed on the outer peripheral surface, and avacuum pad is provided inside the suction hole. The 3-layer laminatedbody and the 4-layer laminated body sucked and held by the separatorcutting drum 20 are sucked by the laminating head via the vacuum pad.The plurality of laminating heads are each rotated around the commoncentral axis of the laminating drum 22, and the individual laminatinghead is driven in the circumferential direction of the drum independentof the other laminating heads, and is further driven in a radialdirection of the drum. That is, the laminating head rotationally conveysthe 3-layer laminated body and the 4-layer laminated body to theposition close to the laminating stage 24 while sucking and holdingthem. When the position close to the laminating stage 24 is reached, therelative speed in the circumferential direction of the drum to thelaminating stage 24 becomes 0, and the laminating head is moved in thedirection of approaching the laminating stage 24 in the radial directionof the drum. The laminating head brings the sucked and held 3-layerlaminated body or 4-layer laminated body into contact with thelaminating stage 24 or, in the case where the 3-layer laminated body orthe 4-layer laminated body is already laminated on the laminating stage24, brings them into contact on the laminated body, turns off suckingand holding force and laminates the sucked and held 3-layer laminatedbody or 4-layer laminated body. Thereafter, the laminating head is movedin the direction of separating from the laminating stage 24 in theradial direction of the drum again, and restarts the rotation.

The above is the whole description.

Note that, for delivery of the 3-layer laminated body and the 4-layerlaminated body from the separator cutting drum 20 to the laminating drum22, a method via the vacuum pad provided on the laminating head of thelaminating drum 22 has been described but it is not limited thereto. Itmay be by the method of providing a groove on the separator cutting drumsimilarly to the positive electrode cutting drum and the negativeelectrode cutting drum and delivering the 3-layer laminated body and the4-layer laminated body to the laminating drum 22 via a belt conveyor.

In addition, the positive electrode plates and the negative electrodeplates may be delivered from the positive electrode cutting drum and thenegative electrode cutting drum to the respective heating drums and thebonding drum not by the belt conveyor but by the vacuum pad. Note that adrum which supplies the electrode assembly or the laminated body of thepositive electrode plate and the negative electrode plate or the like toa suction pad is referred to as a first drum, and a drum comprising thesuction pad is referred also as a second drum.

Next, details of the manufacturing process of the 3-layer laminated bodyand the 4-layer laminated body will be described.

FIG. 3 and FIG. 4 schematically illustrate the manufacturing process ofthe 4-layer laminated body to be a base.

FIG. 3(a) illustrates a situation of negative electrode cutting at thenegative electrode cutting drum 10. On the negative electrode singleplate N comprising the negative electrode current collector and thenegative electrode active material layer, tabs Nt are formed at a fixedinterval. The tab Nt is formed integrally with the negative electrodecurrent collector, and is formed to project from one edge of thenegative electrode current collector (formed to project in the directionorthogonal to an extending direction of the belt-like negative electrodesingle plate N). The negative electrode cutting drum 10 cuts thenegative electrode single plate N at the fixed interval and generatesthe negative electrode plates NP of the first width. At one edge of thenegative electrode plate NP, the tab Nt is formed.

FIG. 3(b) illustrates the situation of positive electrode cutting at thepositive electrode cutting drum 14. On the positive electrode singleplate P comprising the positive electrode current collector and thepositive electrode active material layer, tabs Pt are formed at thefixed interval. The tab Pt is formed integrally with the positiveelectrode current collector, and is formed to project from one edge ofthe positive electrode current collector (formed to project in thedirection orthogonal to the extending direction of the belt-likepositive electrode single plate P). The positive electrode cutting drum14 cuts the positive electrode single plate P at the fixed interval andgenerates the positive electrode plates PP of the second width. At oneedge of the positive electrode plate PP, the tab Pt is formed. A size ofthe positive electrode plate PP is smaller than the size of the negativeelectrode plate NP. In addition, the interval (pitch) of the tab Pt ofthe positive electrode plate PP is smaller than the interval (pitch) ofthe tab Nt of the negative electrode plate NP.

FIG. 3(c) illustrates the situation of bonding at the bonding drum 18.The negative electrode plates NP are arranged at the fixed interval andbonded on the belt-like separator S1, the belt-like separator S2 isarranged and bonded thereon, and the positive electrode plates PP arearranged at the fixed interval and bonded so as to be piled up on thenegative electrode plates NP further. The positive electrode plate PP isarranged inside an existence area of the negative electrode plate NP.Even though the negative electrode plates NP and the positive electrodeplates PP are separate from each other, since the belt-like separatorsS1 and S2 are not cut yet and are still in a belt shape, they are thebelt-like 4-layer laminated body as a whole.

FIG. 3(d) illustrates the situation of cutting at the separator cuttingdrum 20. The separator cutting drum 20 cuts the belt-like 4-layerlaminated body at the fixed interval, that is between the adjacentnegative electrode plates NP, and generates 4-layer laminated bodies 40of the third width for which the separators S1 and S2 are cut off.

FIG. 4 illustrates a configuration of the 4-layer laminated body 40. Theseparator S1 is arranged in a bottom layer, the negative electrode plateNP is laminated thereon, the separator S2 is laminated thereon, and thepositive electrode plate PP is laminated thereon further.

FIG. 5 and FIG. 6 schematically illustrate the manufacturing process ofthe 3-layer laminated body.

FIG. 5(a) illustrates the situation of bonding at the bonding drum 18.The negative electrode plates NP are arranged at the fixed interval andbonded on the belt-like separator S1, and the belt-like separator S2 isarranged and bonded thereon. For the positive electrode plate PP, thepositive electrode plate PP is not arranged at the interval of everyfixed number of pieces. Even though the negative electrode plates NP areseparate from each other, since the belt-like separators S1 and S2 arenot cut yet and are still in the belt shape, they are the belt-like3-layer laminated body as a whole.

FIG. 5(b) illustrates the situation of cutting at the separator cuttingdrum 20. The separator cutting drum 20 cuts the belt-like 3-layerlaminated body at the fixed interval, that is between the adjacentnegative electrode plates NP, and generates 3-layer laminated bodies 30of the third width for which the separators S1 and S2 are cut off. The3-layer laminated body 30 is generated at the interval of every fixednumber of pieces. That is like the 4-layer laminated body 40, the4-layer laminated body 40, the 3-layer laminated body 30, the 4-layerlaminated body . . . .

FIG. 6 illustrates the configuration of the 3-layer laminated body 30.The separator S1 is arranged in the bottom layer, the negative electrodeplate NP is laminated thereon, and the separator S2 is laminatedthereon.

As above, the 3-layer laminated body 30 and 4-layer laminated body 40are generated and are supplied from the separator cutting drum 20 to thelaminating drum 22.

FIG. 7 schematically illustrates a laminating process at the laminatingdrum 22.

When the 3-layer laminated body 30 and 4-layer laminated body 40 in arectangular shape are received from the separator cutting drum 20, thelaminating drum 22 successively arranges and laminates them on thelaminating stage 24. That is, when the 3-layer laminated body 30 of

the separator S1/the negative electrode plate NP/the separator S2

is received, it is inverted upside down to be

the separator S2/the negative electrode plate NP/the separator S1

and arranged on the laminating stage 24.

Next, when the 4-layer laminated body 40 of

the separator S1/the negative electrode plate NP/the separator S2/thepositive electrode plate PP

is received, the laminating drum 22 inverts it upside down to be

the positive electrode plate PP/the separator S2/the negative electrodeplate NP/the separator S1

and arranges and laminates it on the 3-layer laminated body 30 on thelaminating stage 24. Thus, on the laminating stage 24,

the separator S2/the negative electrode plate NP/the separator S1/thepositive electrode plate PP/the separator S2/the negative electrodeplate NP/the separator S1

are laminated. Hereinafter, the laminating drum 22 receives the 4-layerlaminated body 40, inverts it upside down, and arranges and laminates iton the 4-layer laminated body 40 of the laminating stage 24 similarly.Thus,

the separator S2/the negative electrode plate NP/the separator S1/thepositive electrode plate PP/the separator S2/the negative electrodeplate NP/the separator S1/the positive electrode plate PP/the separatorS2/the negative electrode plate NP/the separator S1/ . . . /the positiveelectrode plate PP/the separator S2/the negative electrode plate NP/theseparator S1

are laminated. The laminating drum 22 manufactures the laminatedelectrode assembly by successively laminating one 3-layer laminated body30 and a predetermined number of 4-layer laminated bodies 40 on thelaminating stage 24. By combining and laminating the 3-layer laminatedbody 30 and the 4-layer laminated bodies 40, the laminated electrodeassembly in the rectangular shape for which electrodes at both ends arealways the negative electrode plate NP can be obtained.

Note that the configuration of inversion and lamination is just anexample, and it is needless to say that the other lamination methods arealso possible. For example, the 4-layer laminated body may be laminatedfirst without being inverted and the 3-layer laminated body may belaminated without being inverted at last.

FIG. 8-FIG. 10 more specifically illustrate the laminating process ofthe 3-layer laminated body 30 and the 4-layer laminated body 40.

FIG. 8 illustrates a separator cutting process at the separator cuttingdrum 20. The belt-like 3-layer laminated body 30 and 4-layer laminatedbody 40 bonded at the bonding drum 18 are cut and separated at a roughlymiddle position between the adjacent negative electrode plates NP.Similarly, the belt-like 4-layer laminated bodies 40 are also cut andseparated from each other at the roughly middle position between theadjacent negative electrode plates NP.

FIG. 9 illustrates the cut 3-layer laminated bodies 30 and 4-layerlaminated bodies 40. When it is assumed that a blank of the positiveelectrode plate PP is generated at the interval of every 38 pieces ofthe positive electrode plates PP for example, 37 pieces of the 4-layerlaminated bodies 40 follow after one 3-layer laminated body 30, one3-layer laminated body 30 is generated again thereafter, and 37 piecesof 4-layer laminated bodies 40 are generated further thereafter. When Nis defined as a counter variable, it is the 3-layer laminated body 30when N=1, it is the 4-layer laminated body 40 when N=2, it is the4-layer laminated body 40 when N=3, . . . , it is the 4-layer laminatedbody 40 when N=38, it is the 3-layer laminated body 30 when N=39, and itis the 4-layer laminated body 40 when N=40.

FIG. 10 illustrates the configuration of the laminated electrodeassembly formed by arranging the 3-layer laminated body 30 on thelaminating stage 24 first and successively laminating the 4-layerlaminated bodies 40 thereon. It is the configuration for which one3-layer laminated body 30 and 37 pieces of the 4-layer laminated bodies40 are laminated. The electrodes at both ends of the laminated electrodeassembly are the negative electrode plate NP.

Next, a specific configuration of the electrode cutting head will bedescribed more in detail.

FIG. 11 illustrates a configuration perspective view of the electrodecutting head configuring the positive electrode cutting drum 14. Theplurality of electrode cutting heads are provided in the circumferentialdirection centering on a rotating shaft of the positive electrodecutting drum 14. The electrode cutting head is driven independent of theother electrode cutting heads in the circumferential direction (‘a’direction in the figure) by a motor 14 v provided for each electrodecutting head. Here, instead of the motor 14 v, independent drive may beperformed using a linear motor, a planet gear, a cogged belt or thelike.

On an outer peripheral surface 14 p of the electrode cutting head,suction holes 14 g for sucking and holding the positive electrode singleplate P and the positive electrode plate PP (after being cut) areformed. At the almost center in the direction (‘b’ direction in thefigure) orthogonal to the circumferential direction of the outerperipheral surface 14 p, a groove 14 r is formed along thecircumferential direction, and the suction holes 14 g are not formed atthe groove 14 r. In addition, the electrode cutting head is providedwith a cutting mechanism block 14 t comprising round blades 50 a and 50b. The round blades 50 a and 50 b are a pair of blades. The round blades50 a and 50 b are a set of upper and lower rotary blades, and cut thepositive electrode single plate which is the rectangular electrodeassembly by reciprocating in the ‘b’ direction in the figure while beingrotated. That is, the round blades 50 a and 50 b cut the positiveelectrode single plate by moving forward in the ‘b’ direction in thefigure from an initial position withdrawn from the outer peripheralsurface 14 p, and return to the initial position by moving back in the‘b’ direction in the figure thereafter. The cutting mechanism block 14 tcomprises a cam 14 u engaged with a cam groove formed on a fixed shaftof the positive electrode cutting drum 14. The cutting mechanism block14 t makes the round blades 50 a and 50 b reciprocate along a rail inthe direction (‘b’ direction in the figure) orthogonal to thecircumferential direction at a clearance from the adjacent electrodecutting head via a rack and pinion mechanism, by the cam 14 u movingalong the cam groove accompanying the rotation of the electrode cuttinghead. A reciprocating speed in the ‘b’ direction in the figure of theround blades 50 a and 50 b can be appropriately adjusted by setting agear ratio of the rack and pinion mechanism.

Further, the cutting mechanism block 14 t is connected to a cam 14 w,and after the round blades 50 a and 50 b are moved forward in the ‘b’direction in the figure and cut the positive electrode single plate, thecam 14 w is rotated after the cutting head sucking and holding thepositive electrode plate is moved in the direction of separating fromthe cutting head holding the positive electrode single plate, and thus arotating shaft 14 x of the cutting mechanism block 14 t is rotated.Then, the cutting mechanism block 14 t and the round blades 50 a and 50b are moved in the direction of separating from a cut surface of thepositive electrode single plate accompanying the rotation of therotating shaft 14 x. Thereafter, the round blades 50 a and 50 b aremoved back in the ‘b’ direction in the figure.

FIG. 12 illustrates the case of performing cutting by arranging theupper and lower round blades 50 a and 50 b so as to overlap with eachother in a thickness direction of the positive electrode single plate P.The positive electrode single plate P is configured from a positiveelectrode current collector P1 and positive electrode active materiallayers P2, and the round blade 50 a on an upper side is arranged to sucha depth of passing through the positive electrode active material layerP2 on the upper side and the positive electrode current collector P1. Inaddition, the round blade 50 b on a lower side is arranged to such adepth of passing through the positive electrode active material layer P2on the lower side and the positive electrode current collector P1. Thedepth of the round blade 50 a and the round blade 50 b overlap with eachother in the thickness direction of the positive electrode single plateP. The positive electrode single plate P can be cut even by sucharrangement positions of the round blades 50 a and 50 b, however, thepresent inventors have confirmed that, by the arrangement of the roundblades 50 a and 50 b, there are cases where unneeded projections, thatare burrs, are generated on the cut surface of the positive electrodesingle plate P, and degradation of the laminated electrode assembly maybe caused.

On the other hand, FIG. 13 illustrates the case of performing cutting byarranging the upper and lower round blades 50 a and 50 b so as not tooverlap in the thickness direction of the positive electrode singleplate P. The round blade 50 a on the upper side is arranged to such adepth of passing through the positive electrode active material layer P2on the upper side but not passing through the positive electrode currentcollector P1. In addition, the round blade 50 b on the lower side isarranged to such a depth of passing through the positive electrodeactive material layer P2 on the lower side but not passing through thepositive electrode current collector P1 similarly, and the upper andlower round blades 50 a and 50 b are arranged at a finite distance fromeach other in the thickness direction. In the case of such anarrangement, the upper and lower positive electrode active materiallayers P2 of the positive electrode single plate P are cut by the roundblades 50 a and 50 b, but the positive electrode current collector P1 isnot cut and is maintained in the belt shape as it is even though acutout portion is generated at a part of it. However, the positiveelectrode single plate P is sucked and held on the outer peripheralsurfaces of the plurality of electrode cutting heads, and the electrodecutting heads are moved in the circumferential direction independent ofeach other, adjust the interval between the positive electrode platesPP, and are moved so as to turn the relative linear velocity with thepositive electrode heating drum 16 to roughly 0. When the electrodecutting heads are independently moved in the circumferential direction,mutually reverse tensile force acts on a cutting part of the positiveelectrode single plate P. By the tensile force, the positive electrodecurrent collector P1 is broken with the cutout portion as an origin andresults in being cut. The present inventors have confirmed that, by thearrangement of the round blades 50 a and 50 b illustrated in FIG. 13,burrs are not generated or hardly generated on the cut surface of thepositive electrode single plate P.

Note that, while the upper and lower round blades 50 a and 50 b arearranged so as not to overlap in the thickness direction of the positiveelectrode single plate P in FIG. 13, the arrangement may be such thatthe distance in the thickness direction between the upper and lowerround blades 50 a and 50 b is 0. In other words, when the distance inthe thickness direction of the positive electrode single plate P betweena blade tip of the upper round blade 50 a and the blade tip of the lowerround blade 50 b is L and the thickness of the positive electrodecurrent collector P1 is d, the arrangement is performed so as to bed>L≥0. Here, L<0 means that the upper and lower round blades 50 a and 50b overlap with each other, and means that the upper and lower roundblades 50 a and 50 b cut the positive electrode active material layersP2 on the upper side and the lower side and the positive electrodecurrent collector P1. It can be said that, when it is the positiveelectrode active material layer P2 on the upper side is cut by the roundblade 50 a on the upper side, the positive electrode active materiallayer P2 on the lower side is cut by the round blade 50 b on the lowerside, and the positive electrode current collector P1 is broken by thetensile force without being cut.

FIG. 14 illustrates the situation of cutting the positive electrodesingle plate P at an electrode cutting head 14 a and an electrodecutting head 14 b relating to FIG. 13.

As illustrated in FIG. 14(a), the electrode cutting head 14 a and theelectrode cutting head 14 b are rotated around the rotating shaft centerof the drum while sucking and holding the positive electrode singleplate P on the outer peripheral surface. The positive electrode singleplate P is configured from the positive electrode current collector P1and the positive electrode active material layers P2 formed on the bothsurfaces. When rotational movement is made to a predetermined position,the round blades 50 a and 50 b are moved forward by the cuttingmechanism 14 t provided in the electrode cutting head 14 a, and thepositive electrode active material layers P2 of the positive electrodesingle plate P are cut.

FIG. 14(b) illustrates the situation where the positive electrode activematerial layers P2 are cut by the round blades 50 a and 50 b. At thetime, the positive electrode current collector P1 is not cut yet, and iskept sucked and held on the outer peripheral surface of the electrodecutting head 14 a and the electrode cutting head 14 b in the belt shapeas itis.

Thereafter, as illustrated in FIG. 14(c), the electrode cutting head 14a is accelerated and moved in the circumferential direction of the drumindependent of the electrode cutting head 14 b. By the movement, thetensile force is applied to the positive electrode current collector P1,and the belt-like positive electrode current collector P1 is cut.Thereafter, by the cutting mechanism 14 t provided in the electrodecutting head 14 a, the round blades 50 a and 50 b are moved back. Inthis sense, in the present embodiment, it can be said that cutting ofthe positive electrode single plate P is executed by the combination ofthe movement of the round blades 50 a and 50 b and the movement of theelectrode cutting heads. Note that details of reciprocation of the roundblades 50 a and 50 b will be further described later using FIG. 15.

In the present embodiment, since the positive electrode currentcollector P1 of the positive electrode single plate P is cut by thetensile force and the positive electrode active material layers P2 arecut by the round blades 50 a and 50 b, the cut surface of the positiveelectrode current collector P1 and the cut surfaces of the positiveelectrode active material layers P2 are in cut forms different from eachother.

FIG. 16 illustrates a top view and a side view of the positive electrodeplate PP after being cut. FIG. 16(a) is the top view, the positiveelectrode active material layer P2 is present on a surface, and the tabPt extends from the end. FIG. 16(b) is the side view, and the positiveelectrode active material layers P2 are present at an upper part and alower part of the positive electrode current collector P1 similarly toFIG. 14. Here, the cut surface cut by the electrode cutting head isillustrated as c in the figure.

FIG. 17 illustrates a cross section of the cut surface c in FIG. 16(b).FIG. 17 illustrates the cross section of the cut surface c of thepositive electrode single plate P cut by the electrode cutting head 14 aand the electrode cutting head 14 b relating to FIG. 13. FIG. 17illustrates a range 500 a where the round blade 50 a is brought intocontact by forward movement and a range 500 b where the round blade 50 bis brought into contact by the forward movement. Since the range wherethe round blades 50 a and 50 b rub the positive electrode currentcollector P1 is relatively small, burrs for which an end face of thepositive electrode current collector P1 stretches when the positiveelectrode current collector P1 s rubbed by the round blades 50 a and 50b are suppressed. In addition, as to be described later, by separatingthe round blades 50 a and 50 b from the cut surface after cutting, theround blades 50 a and 50 b do not rub the cut surface when moving back,and damages of the cut surface are suppressed also in this respect.

On the other hand, FIG. 18 schematically illustrates the cut surface cin the case of performing cutting by arranging the round blades 50 a and50 b so as to overlap with each other in the thickness direction of thepositive electrode single plate P as illustrated in FIG. 12, forcomparison. The reciprocation range 500 a of the round blade 50 a andthe reciprocation range 500 b of the round blade 50 b overlap with eachother, and by the round blades 50 a and 50 b rubbing the positiveelectrode current collector P1, the end face of the positive electrodecurrent collector P1 stretches and burrs are generated. By comparingFIG. 17 and FIG. 18, an effect of the arrangement of the round blades inthe present embodiment is clarified.

The round blades 50 a and 50 b cut the positive electrode single plate Pby reciprocating as already described, and FIG. 15 schematicallyillustrates the situation of the reciprocation of the round blades 50 aand 50 b. The round blades 50 a and 50 b are moved forward in thedirection orthogonal to the circumferential direction of the drum fromthe initial position by the cutting mechanism block 14 t and cut thepositive electrode active material layer P2. The round blades 50 a and50 b are moved forward along a moving plane 52.

Next, the round blades 50 a and 50 b return to the initial position byreturn movement. First, after the electrode cutting head 14 a suckingand holding the positive electrode plate PP is moved in the direction ofseparating from the electrode cutting head 14 b holding the positiveelectrode single plate P, the rotating shaft 14 x is rotated by therotation of the cam 14 w illustrated in FIG. 11, and the cuttingmechanism block 14 t and the round blades 50 a and 50 b are moved in thedirection of separating from the positive electrode single plate Paccompanying the rotation of the rotating shaft 14 x. Thereafter, theround blades 50 a and 50 b are moved back in the direction orthogonal tothe circumferential direction of the drum. After the forward movement,the cutting mechanism block 14 t and the round blades 50 a and 50 b aremoved again to the initial position by reverse rotation of the cam 14 w.A forward movement track and a return movement track of the round blades50 a and 50 b are different from each other, and since the round blades50 a and 50 b are not brought into contact with the cut surface of thepositive electrode single plate P and the positive electrode singleplate PP during the return movement, damages of the cut surface can beeffectively suppressed.

In the present embodiment, the round blades 50 a and 50 b areillustrated as the blades of the electrode cutting head, however, theshape of the blades is not limited thereto. In addition, in the presentembodiment, damages of the cut surface are suppressed by making thetracks of the reciprocation of the round blades 50 a and 50 b of theelectrode cutting head be different, however, the configuration ofsuppressing damages of the cut surface is not limited thereto.

FIG. 19 illustrates another blade shape of the electrode cutting head.The upper and lower blades 50 a and 50 b are round blades as a whole,however, a part of the blade is a flat portion. When paying attention tothe blade 50 a, the blade 50 a is configured from an arc portion 50 a 1and a flat portion 50 a 2, the blade is formed at the arc portion 50 al,and the blade is not formed at the flat portion 50 a 2. It is similarfor the blade 50 b, the blade 50 b is configured from an arc portion 50b 1 and a flat portion 50 b 2, the blade is formed at the arc portion 50b 1, and the blade is not formed at the flat portion 50 b 2. The blades50 a and 50 b are both rotated centering on the rotating shaft, and cutthe positive electrode single plate P at the arc portions 50 a 1 and 50b 1 where the blade is formed.

FIG. 20 illustrates the situation of cutting the positive electrodesingle plate P by the rotation of the blades 50 a and 50 b illustratedin FIG. 19. The arc portion 50 a 1 of the blade 50 a and the arc portion50 b 1 of the blade 50 b face each other at the initial position, andthe positive electrode single plate P is cut by the arc portion 50 a 1and the arc portion 50 b 1 as illustrated in (a) and (b) by the rotationof the blades 50 a and 50 b from the initial position during the forwardmovement. The blades 50 a and 50 b are further rotated, and when theyare rotated to the position where the flat portion 50 a 2 and the flatportion 50 b 2 face each other as in (c), the cutting of the positiveelectrode single plate P is ended and the forward movement is completed.During the return movement, while maintaining the state where the flatportion 50 a 2 and the flat portion 50 b 2 face each other, the blades50 a and 50 b are moved to the initial position. Since an inter-axialdistance of the blades 50 a and 50 b is fixed, in the state where theflat portion 50 a 2 and the flat portion 50 b 2 face each other, a gapis generated between the blades 50 a and 50 b. By being moved back whilemaintaining the gap, the blades 50 a and 50 b are not brought intocontact with the cut surface and damages of the cut surface can besuppressed. In this case, the need of the movement (inclination) of thecutting mechanism block 14 t by the rotation of the cam 14 w asillustrated in FIG. 15 can be eliminated.

The positive electrode plate PP is generated by cutting the positiveelectrode single plate P at the positive electrode cutting drum 14 asabove, and the generated positive electrode single plate PP is suppliedto the positive electrode heating drum 16. The positive electrode platePP can be supplied from the positive electrode cutting drum 14 to thepositive electrode heating drum 16 via a belt conveyor for example.

FIG. 21 schematically illustrates supply of the positive electrode platePP from the positive electrode cutting drum 14 to the positive electrodeheating drum 16. In addition, FIG. 22 illustrates a partially enlargedview of FIG. 21, that is an enlarged view of a contact part of thepositive electrode cutting drum 14 and the positive electrode heatingdrum 16.

A belt conveyor 140 is arranged near the contact part of the positiveelectrode cutting drum 14 and the positive electrode heating drum 16,and one end of the belt conveyor 140 is inserted into the groove 14 r ofthe positive electrode cutting drum 14 (see FIG. 11). A width of apulley on one end side of the belt conveyor 140 inserted into the groove14 r is roughly the same as the width of the groove 14 r. A pulley onthe other end side of the belt conveyor 140 is arranged near thepositive electrode heating drum 16. A belt of the belt conveyor 140extends from the groove 14 r of the positive electrode cutting drum 14to vicinity of the positive electrode heating drum 16, turns back at thepulley on the other end side of the belt conveyor 140, and returns intothe groove 14 r of the positive electrode cutting drum 14.

The positive electrode single plate PP is cut at the positive electrodecutting drum 14, sucked and held on the outer peripheral surface, androtationally conveyed. When the positive electrode plate PP isrotationally conveyed and brought into contact with the belt conveyor140 one end of which is inserted into the groove 14 r, the positiveelectrode plate PP gets on the belt conveyor 140, separates from thesurface of the positive electrode cutting drum 14 and rides on the beltconveyor 140. The positive electrode plate PP riding on the beltconveyor 140 is conveyed to the positive electrode heating drum 16 bythe belt conveyor 140, sucked by the suction holes formed on the outerperipheral surface of the positive electrode heating drum 16, moved fromthe belt conveyor 140 to the outer peripheral surface of the positiveelectrode heating drum 16, sucked and held. Note that, while the beltconveyor 140 inserted into the groove 14 r is held by the pulley on oneend side in the description above, a knife edge may be inserted into thegroove 14 r instead of the pulley and the belt conveyor 140 insertedinto the groove 14 r may be held by the knife edge.

The cutting of the positive electrode single plate P at the positiveelectrode cutting drum 14 and the supply of the positive electrode platePP from the positive electrode cutting drum 14 to the positive electrodeheating drum 16 have been described above, and it is similar for thecutting of the negative electrode single plate N at the negativeelectrode cutting drum 10 and the supply of the negative electrode plateNP from the negative electrode cutting drum 10 to the negative electrodeheating drum 12. In addition, also for the cutting of the belt-likeseparator at the separator cutting drum 20, by making the blades 50 aand 50 b move back without being in contact with the cut surface,damages of the cut surface can be suppressed.

Next, the process of supplying the negative electrode plate NP or thepositive electrode plate PP from the negative electrode heating drum 12or the positive electrode heating drum 16 to the bonding drum 18 will bedescribed in detail.

FIG. 23A illustrates the negative electrode heating drum 12 and thebonding drum 18. The negative electrode heating drum 12 receives thenegative electrode plate NP cut at the negative electrode cutting drum10, sucks and holds it on the outer peripheral surface, and heats itwhile rotationally conveying it. Then, at the position close to thebonding drum 18, the heated negative electrode plate NP is successivelybonded at the fixed interval on the belt-like separator S1 which issucked and held on the outer peripheral surface of the bonding drum 18and rotationally conveyed.

The negative electrode heating drum 12 is pivotally supported freelyswingably centering on a drum rotation fulcrum 122, and is swungcentering on the drum rotation fulcrum 122 by a motor 124. In addition,to the negative electrode heating drum 12, a coil spring 120 isinstalled so as to face the drum rotation fulcrum 122. When the negativeelectrode heating drum 12 is swung centering on the rotation fulcrum122, a deflection amount of the coil spring 120 changes, and thuspressurizing force at a pressurizing point which is a contact point ofthe negative electrode heating drum 12 and the bonding drum 18 isadjusted.

While the negative electrode heating drum 12 presses the heated negativeelectrode plate NP to the belt-like separator S1 on the bonding drum 18and bonds the negative electrode plate NP to the separator S1 by thepressurizing force at the pressurizing point, a finite eccentricityexists at the negative electrode heating drum 12 and the finiteeccentricity also exists at the bonding drum 18. When the eccentricityexists, since the deflection amount of the coil spring 120 changes, thenegative electrode plate NP cannot be pressurized and bonded by fixedpressurizing force.

Then, eccentricity amounts of the negative electrode heating drum 12 andthe bonding drum 18 are combined, the negative electrode heating drum 12is swung centering on the rotation fulcrum 122 by rotating the motor 124at all times using the combined value matched with drum rotation, thechange of the pressurizing force at the pressurizing point is offset,and the negative electrode plate NP is pressurized and bonded on thebelt-like separator S1 by almost fixed pressurizing force.

The eccentricity amounts of the negative electrode heating drum 12 andthe bonding drum 18 are measured and obtained beforehand, and stored ina memory of a controller as a table. Drive signals based on acancellation waveform which cancels a composite waveform of theeccentricity amounts of the two drums are supplied to the motor 124,deflection by the eccentricity of the coil spring 120 is suppressed andfluctuation of the pressurizing force is suppressed.

By driving the motor 124 with the cancellation waveform as a drivesignal waveform, the controller can cancel the respective eccentricitiesand press the negative electrode heating drum 12 to the bonding drum 18by the fixed pressurizing force at all times.

However, if the negative electrode heating drum 12 is pressed to thebonding drum 18 by the fixed pressurizing force and the negativeelectrode plate NP is bonded onto the belt-like separator S1, there is arisk that the negative electrode plate NP is damaged by the pressurizingforce at the end of the negative electrode plate NP, that is the end inthe circumferential direction of the drum, in particular. Therefore,damages of both ends of the negative electrode plate NP are prevented byreducing the pressurizing force between the negative electrode heatingdrum 12 and the bonding drum 18 or interrupting the pressurization(turning the pressurizing force to 0) at both ends in thecircumferential direction of the negative electrode plate NP withoutbonding the negative electrode plate NP onto the separator S1 by thefixed pressurizing force.

FIG. 24 illustrates the situation of bonding the negative electrodeplate NP onto the belt-like separator S1 by the fixed pressurizingforce. That is, FIG. 24 illustrates the situation of bonding thenegative electrode plate NP onto the separator S1 without reducing thepressurizing force between the negative electrode heating drum 12 andthe bonding drum 18 or interrupting the pressurization. The separator S1is linearly illustrated in FIG. 24, but is actually sucked and held bythe bonding drum 18 and is in the state of drawing an arc along anarc-shaped outer shape of the bonding drum 18. In addition, one negativeelectrode plate NP is heated on the negative electrode heating drum 12in FIG. 24, however, the plurality of negative electrode plates NP canbe heated.

In FIG. 24(a), the negative electrode heating drum 12 is in directcontact with the separator S1 in an area where the negative electrodeplate NP is not present, and presses the separator S1 by the fixedpressurizing force. When the negative electrode plate NP is rotationallyconveyed in the state, as illustrated in FIG. 24(b), the negativeelectrode heating drum 12 gets on a circumferential direction tip end ofthe negative electrode plate NP first and presses the circumferentialdirection tip end to the separator S1 by the fixed pressurizing force.At the time, the tip end of the negative electrode plate NP is crushedand deformed by the pressurizing force.

Even thereafter, the negative electrode heating drum 12 continuouslypresses the negative electrode plate NP to the separator S1 by the fixedpressurizing force, and bonds the negative electrode plate NP to theseparator S1. Then, as illustrated in FIG. 24(c), a circumferentialdirection rear end of the negative electrode plate NP is also pressed tothe separator S1 by the fixed pressurizing force so that the rear end isalso crushed and deformed by the pressurizing force similarly to the tipend.

In such a manner, when the negative electrode heating drum 12 is pressedto the bonding drum 18 by the fixed pressurizing force at all times,there is a risk that the separator S1 is damaged since the separator S1is pressed even at a part where the negative electrode plate NP is notpresent, and also there is a risk that the circumferential direction tipend and the circumferential direction rear end of the negative electrodeplate NP are pressed and damaged. FIG. 24(c) schematically illustratescrushing at the circumferential direction tip end and thecircumferential direction rear end as a slope shape.

On the other hand, FIG. 25 illustrates the situation of bonding thenegative electrode plate NP to the separator S1 in the presentembodiment. That is, FIG. 25 illustrates the situation of bonding thenegative electrode plate NP onto the separator S1 with the timing ofreducing the pressurizing force between the negative electrode heatingdrum 12 and the bonding drum 18 or interrupting the pressurization. Theseparator S1 is linearly illustrated in FIG. 25, but is actually suckedand held by the bonding drum 18 and is in the state of drawing an arcalong the arc-shaped outer shape of the bonding drum 18. In addition,one negative electrode plate NP is heated on the negative electrodeheating drum 12 also in FIG. 25, however, the plurality of negativeelectrode plates NP can be heated.

In FIG. 25(a), the negative electrode heating drum 12 regulates thepressurizing force at the pressurizing point in the area where thenegative electrode plate NP is not present so as not to press thenegative electrode heating drum 12 to the bonding drum 18. Even when thenegative electrode plate NP is rotationally conveyed and thecircumferential direction tip end of the negative electrode plate NP isbrought into contact with the separator S1 in the state, regulation ofthe fixed pressurizing force is maintained as it is. Accordingly, thecircumferential direction tip end of the negative electrode plate NP isnot pressed.

In FIG. 25(b), when the negative electrode plate NP is rotationallyconveyed further and a center portion other than the circumferentialdirection tip end is brought into contact with the separator S1, thenegative electrode heating drum 12 is pressed to the bonding drum 18 bythe fixed pressurizing force. Thus, the negative electrode plate NP isbonded to the separator S1.

In FIG. 25(c), when the negative electrode plate NP is rotationallyconveyed further and the circumferential direction rear end is broughtinto contact with the separator S1, the pressurizing force is regulatedand the negative electrode heating drum 12 is not pressed to the bondingdrum 18. Accordingly, the circumferential direction rear end of thenegative electrode plate NP is not pressed.

As above, by pressing only the center portion of the negative electrodeplate NP by the fixed pressurizing force, regulating the fixedpressurizing force at both ends, that are the circumferential directiontip end and the circumferential direction rear end, of the negativeelectrode plate NP and not pressing both ends, damages of both ends ofthe negative electrode plate NP are prevented. In addition, byregulating the fixed pressurizing force also in the area where thenegative electrode plate NP is not present, damages of the separator S1are also prevented.

Separately from cancellation of the eccentricity amounts of the negativeelectrode heating drum 12 and the bonding drum 18, the controllerreduces the pressurizing force between the negative electrode heatingdrum 12 and the bonding drum 18 or interrupts the pressurization at bothends of the negative electrode plate NP. A mechanism of reducing thepressurizing force between the negative electrode heating drum 12 andthe bonding drum 18 or interrupting the pressurization will be describedbased on FIG. 23B and FIG. 23C.

FIG. 23B and FIG. 23C are a perspective view and a rear elevation of apressurizing force adjusting mechanism, and a column α of the bondingdrum 18 is provided with a cam mechanism 80. To a column β of thenegative electrode heating drum 12, a swing arm 82 is attached as an armengaged with the cam mechanism 80, and the swing arm 82 pivotallysupports a roller 84. The surface of the cam mechanism 80 and the roller84 are in contact. A surface shape of the cam mechanism 80 is polygonalor has projections at a predetermined interval. In the cam mechanism 80,corner portions of a polygon or the projections operate to reduce thepressurizing force between the negative electrode heating drum 12 andthe bonding drum 18 or to interrupt the pressurization. The cammechanism 80 is driven by a motor independent of the drive of the motor124. By the operation of the cam mechanism 80, a distance between thenegative electrode heating drum 12 and the bonding drum 18 iscontrolled, and the pressurizing force to the negative electrode plateNP can be reduced or the pressurization can be interrupted.

The pressurizing force between the negative electrode heating drum 12and the bonding drum 18 is kept fixed by the drive of the motor 124,however, the distance between the column β to which the negativeelectrode heating drum 12 is attached and the column a to which thebonding drum 18 is attached fluctuates. Accompanying the fluctuation ofthe distance, the fluctuation of the distance between the cam mechanism80 and the roller 84 is generated and there may be a case where thepressurizing force between the negative electrode heating drum 12 andthe bonding drum 18 cannot be reduced or the pressurization cannot beinterrupted at a predetermined timing.

In order to keep the distance between the cam mechanism 80 and theroller 84 fixed, the swing arm 82 is provided with a roller 86, and aninclination member 88, a roller 90 and a cam mechanism 92 drivableindependent of the column β of the negative electrode heating drum 12are provided on the side of the column β. The roller 86 is in contactwith an inclined surface of the inclination member 88. The roller 90 isattached to the inclination member 88 and is in contact with the cammechanism 92. Since the inclination member 88 is moved up and down bythe cam mechanism 92 driven by the motor, the swing arm 82 is swung viathe roller 86 in contact with the inclined surface of the inclinationmember 88.

While the column β and the inclination member 88 are moved to right andleft by the drive of the motor 124 according to a cancellation waveform,the inclined surface of the inclination member 88 is also moved up anddown by the drive of the motor (not illustrated) which moves the cammechanism 92 up and down also according to the cancellation waveform,and thus the fluctuation of the position of the roller 86 can besuppressed. Since the fluctuation of the position of the roller 86 issuppressed, the fluctuation of the distance between the roller 84 andthe cam mechanism 80 can be suppressed.

Note that the method of bonding the negative electrode plate NP to thebelt-like separator S1 by the fixed pressurizing force by the drive ofthe motor 124 and suppressing damages of both ends of the negativeelectrode plate NP by the drive of the cam mechanism 80 has beendescribed in the description above, however, it is possible to suppressdamages of both ends of the negative electrode plate NP after bondingthe negative electrode plate NP to the belt-like separator S1 by thefixed pressurizing force even by driving the motor 124.

The positions of the negative electrode plates NP and the intervalbetween the negative electrode plates NP at the negative electrodeheating drum 12 can be detected by a camera arranged near the negativeelectrode heating drum 12 for example. The controller which monitors andcontrols the entire manufacturing device can also receive position dataand interval data of the negative electrode plate NP detected by thecamera, and control permission/regulation of the fixed pressurizingforce (or ON/OFF of the fixed pressurizing force) using the receivedposition data and interval data.

It is similar for a relation of the positive electrode heating drum 16and the bonding drum 18, and the controller defines the drive signalwaveform for cancelling the eccentricity amounts of the positiveelectrode heating drum 16 and the bonding drum 18 and pressing thepositive electrode heating drum 16 to the bonding drum 18 by the fixedpressurizing force as a reference, superimposes the drive signalwaveform for regulating the fixed pressurizing force at both ends of thepositive electrode plate PP and in the area where the positive electrodeplate PP is not present, and performs driving.

Further, while the thermocompression bonding roller 19 is a roller forpressing and thermocompression-bonding the belt-like separator S1/thenegative electrode plate NP/the belt-like separator S2, the controllercan also drive the roller by the drive signal waveform for regulatingthe fixed pressurizing force at both ends of the negative electrodeplate NP and in the area where the negative electrode plate NP is notpresent.

Note that, while the case where the drum rotation fulcrum 122, the motor124 and the coil spring 120 are installed to the negative electrodeheating drum 12 has been described in the description relating to FIG.23A, they may be provided on the side of the bonding drum 18. However,while FIG. 23A illustrates the state where the negative electrodeheating drum 12 and the bonding drum 18 are in contact, there is a casewhere the drum which supplies the positive electrode plate is also incontact with the bonding drum 18. In such a case, the drum rotationfulcrum, the motor and the coil spring are preferably provided on thedrum which supplies the positive electrode plate and the drum whichsupplies the negative electrode plate.

FIG. 26-FIG. 28 illustrate a pressurizing range at the negativeelectrode heating drum 12, the thermocompression bonding roller 19 andthe positive electrode heating drum 16.

FIG. 26 illustrates the pressurizing range when bonding the belt-likeseparator S1 and the negative electrode plate NP by the negativeelectrode heating drum 12 and the bonding drum 18 by a dashed line. Ofthe negative electrode plate NP, both ends in a longitudinal directionof the belt-like separator S1 are not pressurized, and the other area ispressurized and pressed. In other words, of four sides of the negativeelectrode plate NP in the rectangular shape, the two opposite sides,that are the two opposite sides in the longitudinal direction of thebelt-like separator S1, are not pressurized, and the two opposite sidesin the direction orthogonal to the longitudinal direction arepressurized. Of the four sides of the negative electrode plate NP in therectangular shape, the two pressurized sides are bonded with theseparator S1 at the pressurized parts, and the two sides that are notpressurized are not bonded with the separator S1.

FIG. 27 illustrates the pressurizing range when bonding the belt-likeseparator S1, the negative electrode plate NP and the belt-likeseparator S2 by the thermocompression bonding roller 19 and the bondingdrum 18 by a dashed line. Similarly to the case of FIG. 26, of thenegative electrode plate NP, both ends in the longitudinal direction ofthe belt-like separators S1 and S2 are not pressurized, and the otherarea is pressurized and pressed. In other words, of the four sides ofthe negative electrode plate NP in the rectangular shape, the twoopposite sides, that are the two opposite sides in the longitudinaldirection of the belt-like separators S1 and S2, are not pressurized,and the two opposite sides in the direction orthogonal to thelongitudinal direction are pressurized. Of the four sides of thenegative electrode plate NP in the rectangular shape, the twopressurized sides are bonded with the separator S2 at the pressurizedparts, and the two sides that are not pressurized are not bonded withthe separator S1.

FIG. 28 illustrates the pressurizing range when bonding the belt-likeseparator S1, the negative electrode plate NP, the belt-like separatorS2 and the positive electrode plate PP by the positive electrode heatingdrum 16 and the bonding drum 18 by a dashed line. Of the positiveelectrode plate PP, both ends in the longitudinal direction of thebelt-like separators S1 and S2 are not pressurized, and the other areais pressurized and pressed. In other words, of the four sides of thepositive electrode plate PP in the rectangular shape, the two oppositesides, that are the two opposite sides in the longitudinal direction ofthe belt-like separators S1 and S2, are not pressurized, and the twoopposite sides in the direction orthogonal to the longitudinal directionare pressurized. Of the four sides of the positive electrode plate PP inthe rectangular shape, the two pressurized sides are bonded with theseparators S1 and S2 at the pressurized parts, and the two sides thatare not pressurized are not bonded with the separators S1 and S2.

Since the size of the positive electrode plate PP is smaller than thesize of the negative electrode plate NP, the pressurizing range in FIG.28 is smaller than the pressurizing range in FIG. 26. As above, the3-layer laminated body 30 and the 4-layer laminated body 40 aremanufactured while the pressurizing range is controlled.

Next, the laminating process at the laminating drum 22 and thelaminating stage 24 will be described in more detail.

FIG. 29 illustrates a configuration perspective view of the laminatingdrum 22. The laminating drum 22 is arranged closely to the separatorcutting drum 20, and is rotated roughly the same as the linear velocityof the separator cutting drum 20. The laminating drum 22 is configuredby the plurality of laminating heads which are rotated around the drumrotation center. The number of the laminating heads is arbitrary, andthe laminating drum 22 is configured from 12 laminating heads 22 a, 22b, 22 c, 22 d, 22 e, 22 f, 22 g, 22 h, 22 i, 22 j, 22 k and 22 m forexample. Each laminating head is configured from an arm (spoke)connected to a drum center axis (hub) and a holding portion connected tothe other end of the spoke. For each laminating head, the longitudinalsection shape is roughly T-shaped by the arm and the holding portion,and the suction holes for sucking and holding the 3-layer laminated body30 and the 4-layer laminated body 40 generated by being cut by theseparator cutting drum 20 are formed on the outer peripheral surface ofthe holding portion. The holding portion is connected freely swingablyin the circumferential direction to the arm.

The plurality of laminating heads 22 a-22 m are each rotated around thecentral axis of the laminating drum 22, and the individual laminatinghead is driven in the circumferential direction of the drum independentof the other laminating heads, and is further driven in the radialdirection of the drum. That is, the individual laminating headrotationally conveys the 3-layer laminated body 30 and the 4-layerlaminated body 40 to the position close to the laminating stage 24 whilesucking and holding them. When the position close to the laminatingstage 24 is reached, the relative speed in the circumferential directionof the drum to the laminating stage 24 becomes 0, and the individuallaminating head is moved in the direction of approaching the laminatingstage 24 in the radial direction of the drum. The individual laminatinghead which approaches the laminating stage 24 brings the sucked and held3-layer laminated body 30 or 4-layer laminated body 40 into contact withthe laminating stage 24 or, in the case where the 3-layer laminated body30 or the 4-layer laminated body 40 is already laminated on thelaminating stage 24, into contact on the laminated body, turns off thesucking and holding force and laminates the sucked and held 3-layerlaminated body 30 or 4-layer laminated body 40. Thereafter, theindividual laminating head is moved in the direction of separating fromthe laminating stage 24 in the radial direction of the drum.

FIG. 30-FIG. 33 illustrate a basic operation of the laminating heads 22a-22 m. Hereinafter, in the description of the operation of theindividual laminating head, “the radial direction of the drum” and “theradial direction of the laminating drum 22” are appropriately referredto as “the radial direction”.

As illustrated in FIG. 30, the laminating heads 22 a-22 m are rotatedaround the rotation center axis of the laminating drum 22 at the fixedangular velocity, and when the predetermined position is reached,accelerated in the circumferential direction independent of the otherlaminating heads. For example, when paying attention to the laminatinghead 22 a, the laminating head 22 a is accelerated when thepredetermined position in the circumferential direction is reached,approaches the adjacent laminating head 22 m on the upstream side of therotation direction, and separates from the adjacent laminating head 22 bon the downstream side of the rotation direction.

After the acceleration, when the laminating head 22 a reaches theposition close to the laminating stage 24 as illustrated in FIG. 31, forthe laminating head 22 a, the relative speed in the circumferentialdirection of the drum to the laminating stage 24 becomes 0. At the closeposition, the 3-layer laminated body 30 or the 4-layer laminated body 40sucked and held on the outer peripheral surface is laminated on thelaminating stage 24. In more detail, when approaching the position closeto the laminating stage 24, the outer peripheral surface of the holdingportion is swung to an angle to be roughly parallel to a stage surfaceof the laminating stage 24, and the laminating head 22 a brings theouter peripheral surface of the holding portion close to the stagesurface of the laminating stage 24 by being moved in the direction ofthe laminating stage 24 by the arm moving in the radial direction whilemaintaining the state that the outer peripheral surface of the holdingportion is roughly parallel to the stage surface of the laminating stage24, and laminates the 3-layer laminated body 30 or the 4-layer laminatedbody 40 sucked and held on the outer peripheral surface onto thelaminating stage 24.

FIG. 32 and FIG. 33 illustrate the state after the 3-layer laminatedbody 30 or the 4-layer laminated body 40 is laminated on the laminatingstage 24. The adjacent laminating head 22 b on the rotation directiondownstream side of the laminating head 22 a is accelerated since it hasreached the predetermined position, and approaches the laminating head22 a. After laminating the 3-layer laminated body 30 or the 4-layerlaminated body 40 on the laminating stage 24, the laminating head 22 ais rotated in the circumferential direction and withdrawn from theposition close to the laminating stage 24. In more detail, thelaminating head 22 a is moved in such a direction that the outerperipheral surface separates from the position close to the stagesurface of the laminating stage 24 by the arm moving in the radialdirection, and is moved in the rotation direction and withdrawn so thatthe laminating head 22 a does not interfere with the laminating head 22b. After withdrawal from the close position, the outer peripheralsurface of the holding portion is swung in the opposite direction andreturns.

FIG. 34 illustrates a specific configuration example of the laminatinghead 22 a. It is similar also for the other laminating heads 22 b-22 m.

The laminating head 22 a comprises two arms 22 a 1 and 22 a 2 and aholding portion 22 a 3. The arms 22 a 1 and 22 a 2 extend in parallel tothe radial direction of the laminating drum 22, the arm 22 a 1 and thearm 22 a 2 are rotationally driven integrally in the circumferentialdirection of the drum by a cam mechanism 22 a 4, and the arm 22 a 1 andthe arm 22 a 2 are driven to swing in the circumferential direction by acam mechanism 22 a 5. On ends in the radial direction of the arm 22 a 1and the arm 22 a 2, an outer peripheral surface 22 a 3 is freelyswingably provided. The outer peripheral surface 22 a 3 is rotatedtogether with the rotation in the circumferential direction of the arm22 a 1 and the arm 22 a 2, and is swung/moved together with the swingand radial direction movement of the arm 22 a 1 and the arm 22 a 2.Further, the outer peripheral surface 22 a 3 is swung to the arm 22 a 1and the arm 22 a 2 by a cam mechanism 22 a 6.

FIG. 35 illustrates a time change of the position of the laminating head22 a. In the figure, a horizontal axis indicates time, and a verticalaxis indicates the position (angle) in the circumferential direction ofthe drum.

From a certain reference position to a position θ1, the laminating head22 a is rotated at the fixed angular velocity. The outer peripheralsurface 22 a 3 is rotated while sucking and holding the 3-layerlaminated body 30 or the 4-layer laminated body 40.

Next, when the predetermined position θ1 is reached, the laminating head22 a is accelerated in the circumferential direction, and the outerperipheral surface 22 a 3 is also accelerated accompanying that. Duringthe time, since the adjacent laminating head 22 b on the rotationdirection downstream side is continuously rotated at the fixed angularvelocity, a clearance between the laminating head 22 a and thelaminating head 22 b increases. It can be said that, by theacceleration, the laminating head 22 a generates/secures stop time atthe position close to the laminating stage 24, that is lamination timeof the 3-layer laminated body 30 or the 4-layer laminated body 40 ontothe laminating stage 24. In addition, during the acceleration, the outerperipheral surface 22 a 3 is swung to the arms 22 a 1 and 22 a 2, andthe surface sucking and holding the 3-layer laminated body 30 or the4-layer laminated body 40 is inclined so as to be roughly parallel tothe stage surface of the laminating stage 24.

Next, when a position θ2 close to the laminating stage 24 is reached,the laminating head 22 a is stopped at the position (needless to say,deceleration control is executed before stop, however, it is omitted forconvenience of the description), moves the arm 22 a 1 and the arm 22 a 2in the radial direction to bring the outer peripheral surface close tothe stage surface of the laminating stage 24, turns off suction force ofthe outer peripheral surface, and laminates the 3-layer laminated body30 or the 4-layer laminated body 40 on the laminating stage 24. At thetime, by the claws provided on the laminating stage 24, the corner partsof the 3-layer laminated body 30 or the 4-layer laminated body 40supplied from the laminating stage 22 a are pressed and held. Themovement of the claws of the laminating stage 24 linked with themovement of the laminating head 22 a will be further described later.

After laminating the 3-layer laminated body 30 or the 4-layer laminatedbody 40, the laminating head 22 a is accelerated and rotated so as towithdraw to a predetermined position θ3. During the withdrawal, theouter peripheral surface 22 a 3 is swung to the arms 22 a 1 and 22 a 2,and the surface sucking and holding the 3-layer laminated body 30 or4-layer laminated body 40 is inclined and returned to an initial angle.

Then, when the predetermined position θ3 is reached, the laminating head22 a is rotated at the fixed angular velocity again until thepredetermined position θ1 is reached again. During the period, thelaminating head 22 a receives a new 3-layer laminated body 30 or 4-layerlaminated body 40 from the separator cutting drum 20, sucks and holds iton the outer peripheral surface 22 a 3, and then reaches thepredetermined position θ1.

Next, the operation of the laminating stage 24 will be described in moredetail.

FIG. 36 illustrates a configuration perspective view of the laminatingstage 24. The laminating stage 24 is arranged right under the laminatingdrum 22. The laminating stage 24 comprises a stage surface 24 g wherethe 3-layer laminated body 30 and the 4-layer laminated body 40 arelaminated, and claws 24 a-24 d which press the 3-layer laminated body 30and the 4-layer laminated body 40 laminated on the stage surface 24 gfrom above and hold them.

The stage surface 24 g forms a rectangular outer shape corresponding tothe rectangular shape of the 3-layer laminated body 30 and the 4-layerlaminated body 40, and is arranged within a roughly horizontal plane.The 3-layer laminated body 30 or the 4-layer laminated body 40 suckedand held on the outer peripheral surface of the laminating heads 22 a-22m of the laminating drum 22 is positioned on the rectangular stagesurface 24 g and laminated. Specifically, when two orthogonal axeswithin the horizontal plane are defined as an X axis and a Y axis andthe rotation direction of the X axis with a certain direction within thehorizontal plane as a reference is defined as a 0 direction, the stagesurface 24 g is driven in X axis and Y axis directions and also drivenin the 0 direction, that is, moved and rotationally driven within thehorizontal plane, and is thus positioned so as to match a sucked andheld posture of the 3-layer laminated body 30 or the 4-layer laminatedbody 40 sucked and held on the outer peripheral surface of thelaminating heads 22 a-22 m of the laminating drum 22. For a laminationorder, for example, the 3-layer laminated body 30 is arranged on thestage surface 24 g first, then the 4-layer laminated body 40 islaminated on the 3-layer laminated body 30 and then the new 4-layerlaminated body 40 is laminated on the already laminated 4-layerlaminated body 40.

The claws 24 a-24 d are arranged respectively at four corners of therectangular stage surface 24 g. The claws 24 a-24 d each form a roughlyL-shaped planar shape, are supported freely swingably in the 0 directioncentering on the shaft, and are also supported freely movably in avertical direction (hereinafter, it is appropriately referred to as avertically upper direction or a vertically lower direction). A drivesource of the claws 24 a-24 d may be loaded on the laminating stage 24similarly to a drive source for driving and positioning the stagesurface 24 g in the X-Y direction and the 0 direction, but may be loadedoutside the laminating stage 24 in order to reduce weight of thelaminating stage 24. In the case of loading the drive source of the 24a-24 d outside the laminating stage 24, the external drive source andthe claws 24 a-24 d are connected by wires 24 e via a cam mechanism,drive force from the external drive source is transmitted by the wires24 e and the claws 24 a-24 d are swung and vertically driven. The claws24 a-24 d are pressurized in the vertically lower direction by a spring24 f, and the 3-layer laminated body 30 and the 4-layer laminated body40 on the stage surface 24 g are pressed and held by the pressurizingforce.

FIG. 37 illustrates a plane arrangement of the stage surface 24 g andthe claws 24 a-24 d of the laminating stage 24. When the stage surface24 g is in the rectangular shape, the claws 24 a-24 d are arranged atthe four corner parts of the rectangular shape. The claw 24 a and theclaw 24 c are arranged on a diagonal line of the stage surface 24 g, andthe claw 24 b and the claw 24 d are arranged on the other diagonal lineof the stage surface 24 g. The claw 24 a and the claw 24 c are pairedand are a first claw pair, and the claw 24 b and the claw 24 d arepaired and are a second claw pair. The claws 24 a-24 d are each freelyswingable (freely turnable) clockwise and counterclockwise centering onthe rotating shaft. When paying attention to the claw 24 d, it isarranged at an upper left corner of the stage surface 24 g, and theshaft is positioned within an area defined by extended lines of twoopposite long sides of the stage surface 24 g. The claw 24 d iswithdrawn to the outside (withdrawn position) of the existence area ofthe stage surface 24 g at the initial position, is partially positionedinside the existence area of the stage surface 24 g by swingingclockwise, and presses the laminated body (the 3-layer laminated body 30and the 4-layer laminated body 40) laminated on the stage surface 24 gat a pressing position. In addition, when paying attention to the claw24 a, it is arranged at an upper right corner of the stage surface 24 g,and the shaft is positioned within the area defined by the extendedlines of the two opposite long sides of the stage surface 24 g. The claw24 a is withdrawn to the outside (withdrawn position) of the existencearea of the stage surface 24 g at the initial position, is partiallypositioned inside the existence area of the stage surface 24 g byswinging counterclockwise, and presses and holds the laminated bodylaminated on the stage surface 24 g. The claw 24 b is operated the sameas the claw 24 d, and the claw 24 c is operated the same as the claw 24a.

When pressing and holding the laminated body, the claw 24 a and the claw24 c, and the claw 24 b and the claw 24 d positioned on the diagonalline of the stage surface 24 g are swung within the horizontal plane andalso vertically moved respectively as sets. That is, the first claw pairof the claw 24 a and the claw 24 c is swung and presses and holds thelaminated body, but the second claw pair of the claw 24 b and the claw24 d does not hold the laminated body which is newly laminated since itis pressing and holding the laminated body which is already laminated atthe time. Then, when the new laminated body is laminated next, thesecond claw pair of the claw 24 b and the claw 24 d is swung, withdrawnfrom the stage surface 24 g, moved in the upper direction and swungagain, and presses and holds the laminated body which is newlylaminated.

FIG. 38 illustrates the operation of pressing and holding the laminatedbody by the claws 24 a-24 d.

FIG. 38(a) illustrates the state of pressing and holding a 3-layerlaminated body 30-1 laminated on the stage surface 24 g. When the first3-layer laminated body 30-1 is laminated on the stage surface 24 g, theclaw 24 a and the claw 24 c are swung counterclockwise and arranged onthe 3-layer laminated body 30-1, press the 3-layer laminated body 30-1in the vertically lower direction from above by the pressurizing forceof the spring 24 f, and hold the 3-layer laminated body 30-1.

FIG. 38(b) illustrates the state where a new 4-layer laminated body 40-2is laminated on the 3-layer laminated body 30-1 newly from the state ofFIG. 38(a). Since the 4-layer laminated body 40-2 is laminated over theclaws 24 a and 24 c pressing and holding the 3-layer laminated body30-1, the 4-layer laminated body 40-2 is laminated so as to cover a partof the claws 24 a and 24 c.

FIG. 38(c) illustrates the state of pressing and holding the 4-layerlaminated body 40-2. While the 3-layer laminated body 30-1 is keptpressed and held by the claws 24 a and 24 c, the claws 24 b and 24 d aremoved in the vertically upper direction, swung clockwise further, andarranged on the 4-layer laminated body 40-2. The claws 24 b and 24 dpress the 4-layer laminated body 40-2 in the vertically lower directionfrom above by the pressurizing force of the spring 24 f and hold it.

FIG. 38(d) illustrates the state where the claws 24 a and 24 c arewithdrawn from the state of FIG. 38(c). After the 4-layer laminated body40-2 is pressed and held by the claws 24 b and 24 d, the claws 24 a and24 c no longer need to press and hold the 3-layer laminated body 30-1,and need to be withdrawn from the stage surface 24 g so as not toobstruct the laminated body to be newly laminated next. Then, the claws24 a and 24 c are moved in the vertically upper direction, swungclockwise and withdrawn from the stage surface 24 g. At the time, sincethe 3-layer laminated body 30-1 and the 4-layer laminated body 40-2 arepressed and held by the claws 24 b and 24 d, the laminating position isnot shifted by the swing of the claws 24 a and 24 c.

FIG. 38(e) illustrates the state where a next laminated body 40-3 islaminated on the 4-layer laminated body 40-2 newly from the state ofFIG. 38(d). Since the 4-layer laminated body 40-3 is laminated over theclaws 24 b and 24 d pressing and holding the 4-layer laminated body40-2, the 4-layer laminated body 40-3 is laminated so as to cover a partof the claws 24 b and 24 d.

FIG. 38(f) illustrates the state of pressing and holding the 4-layerlaminated body 40-3. While the 4-layer laminated body 40-2 is keptpressed and held by the claws 24 b and 24 d, the claws 24 a and 24 c aremoved in the vertically upper direction, swung counterclockwise further,and arranged on the 4-layer laminated body 40-3. The claws 24 a and 24 cpress the 4-layer laminated body 40-3 in the vertically lower directionfrom above by the pressurizing force of the spring 24 f and hold it. Byrepeating the above-described operation, the 4-layer laminated bodies40-2, 40-3, . . . are laminated successively on the 3-layer laminatedbody 30-1.

The claws 24 a-24 d and the respective shafts in the present embodimentare arranged within the area defined by the extended lines of the twoopposite long sides of the stage surface 24 g as illustrated in FIG. 37,however, without being limited thereto, they may be arranged outside thearea defined by the extended lines of the two opposite long sides of thestage surface 24 g. The inside of the area defined by the extended linesof the two opposite long sides of the stage surface 24 g is the areaincluding also the stage surface 24 g. The outside of the area definedby the extended lines of the two opposite long sides of the stagesurface 24 g is the area not including the stage surface 24 g.

FIG. 39 illustrates a plan view in the case where the respective shaftsof the claws 24 a-24 d are arranged outside the area defined by theextended lines of the two opposite long sides of the stage surface 24 g.When paying attention to the claw 24 d, it is arranged at the upper leftcorner of the stage surface 24 g, and the shaft is positioned outsidethe area defined by the extended lines of the two opposite long sides ofthe stage surface 24 g. The attention should be paid to a differencebetween the position of the claw 24 d in FIG. 37 and the position of theclaw 24 d in FIG. 39. It is similar for the other claws 24 a-24 c. Notethat, in FIG. 39, the respective shafts of the claws 24 a-24 d arepositioned outside the area defined by the extended lines of twoopposite short sides of the stage surface 24 g. The outside of the areadefined by the extended lines of the two opposite short sides of thestage surface 24 g is the area not including the stage surface 24 g.

When the respective shafts of the claws 24 a-24 d are arranged outsidethe area defined by the extended lines of the two opposite long sides ofthe stage surface 24 g, in the case where the laminated body sucked andheld on the outer peripheral surface of the laminating heads 22 a-22 mof the laminating drum 22 is laminated onto the stage surface 24 g, thelaminated body does not enter from right above the stage surface 24 g,and the laminated body enters from diagonally above the stage surface 24g since the outer peripheral surface is moved along the circumference.When the radius of the laminating drum 22 is sufficiently largerelatively compared to the size of the stage surface 24 g, it is almostthe same as the entry of the laminated body from a side direction of thestage surface 24 g.

FIG. 39 schematically illustrates the situation where the laminated bodyenters from the side direction of the stage surface 24 g in such amanner. The 4-layer laminated body 40-2 is laminated on the stagesurface 24 g, and the 4-layer laminated body 40-2 is pressed and held bythe claws 24 a and 24 c. In the case of newly laminating the next4-layer laminated body 40-3, the 4-layer laminated body 40-3 sucked andheld on the outer peripheral surface of the laminating drum 22 entersfrom the side (from below in the figure) of the stage surface 24 g. Theshafts of the claws 24 b and 24 d are arranged outside the area definedby the extended lines of the two opposite long sides of the stagesurface 24 g. The claws 24 b and 24 d are moved in the vertically upperdirection and swung, and do not collide with the next 4-layer laminatedbody 40-3 entering from the side even when they are positioned on thestage surface 24 g. The claws 24 b and 24 d are not obstacles to the4-layer laminated body 40-3. Accordingly, when laminating the 4-layerlaminated body 40-3, the claws 24 b and 24 d do not need to be withdrawnto the outside (withdrawn position) of the existence area of the stagesurface 24 g. The claws 24 b and 24 d are positioned on the stagesurface 24 g (standby position) and made to stand by, and the claws 24 band 24 d can press and hold the 4-layer laminated body 40-3 by thepressurizing force of the spring 24 f promptly after the 4-layerlaminated body 40-3 is laminated on the 4-layer laminated body 40-2.

FIG. 40-FIG. 44 illustrate the operation of the claws 24 a-24 d of thelaminating stage 24 linked with the movement of the laminating heads 22a-22 m in more detail. In the figures, the movement of the laminatinghead 22 a among the laminating heads 22 a-22 m is illustrated, however,it is also similar for the other laminating heads 22 b-22 m.

FIG. 40 illustrates a side view of the case where the 3-layer laminatedbody 30-1 and the 4-layer laminated body 40-2 are already laminated onthe stage surface 24 g of the laminating stage 24 and the 4-layerlaminated body 40-3 is to be newly laminated next by the laminating head22 a. While the figure illustrates the claws 24 c and 24 d, the claw 24a is operated similarly to the claw 24 c, and the claw 24 b is operatedsimilarly to the claw 24 d.

The claw 24 c presses and holds the 3-layer laminated body 30-1 and the4-layer laminated body 40-2 on the stage surface 24 g by thepressurizing force of the spring 24 f On the other hand, the claw 24 dis moved in the vertically upper direction and swung around the shaftand is in a standby state so as to be partially positioned above thestage surface 24 g (withdrawn position). The laminating head 22 a isrotated while sucking and holding the 4-layer laminated body 40-3 on theouter peripheral surface, is accelerated when the specific position isreached, and approaches the position close to the stage surface 24 g.When the laminating head 22 a approaches the position close to the stagesurface 24 g, the holding portion 22 a 3 is swung to the arms 22 a 1 and22 a 2 and the outer peripheral surface is made roughly parallel to thestage surface 24 g while avoiding a collision with the stage surface 24g.

FIG. 41 is the case where the laminating head 22 a reaches the positionclose to the stage surface 24 g.

The arms 22 a 1 and 22 a 2 of the laminating head 22 a are moved in theradial direction of the laminating drum 22, the holding portion 22 a 3is also moved in the vertically lower direction, and the outerperipheral surface of the holding portion 22 a 3 further gets closer tothe stage surface 24 g. At the time, the claw 24 d is in the standbystate above the stage surface 24 g (withdrawn position), and the claw 24c maintains the state of pressing and holding the 3-layer laminated body30-1 and the 4-layer laminated body 40-2. Then, from the state, asillustrated in FIG. 42, the laminating head 22 a laminates the 4-layerlaminated body 40-3 onto the 3-layer laminated body 30-1 and the 4-layerlaminated body 40-2 on the stage surface 24 g, and turns off the suctionforce of the holding portion 22 a 3. The movement in the verticallylower direction of the holding portion 22 a 3 may be temporarily stoppedafter the movement in the vertically lower direction of the holdingportion 22 a 3 is started and before the 4-layer laminated body 40-3 islaminated on the 3-layer laminated body 30-1 and the 4-layer laminatedbody 40-2 on the stage surface 24 g. By the temporary stop, an impactwhen the 4-layer laminated body 40-3 is laminated on the 3-layerlaminated body 30-1 and the 4-layer laminated body 40-2 on the stagesurface 24 g can be mitigated.

FIG. 43 illustrates the state where the 4-layer laminated body 40-3 islaminated on the 3-layer laminated body 30-1 and the 4-layer laminatedbody 40-2. Since the claw 24 c (and the claw 24 a) presses and holds the3-layer laminated body 30-1 and the 4-layer laminated body 40-2, the4-layer laminated body 40-3 is laminated on the claw 24 c (and the claw24 a). In addition, the claw 24 d (and the claw 24 b) is in the standbystate above the stage surface 24 g. When the 4-layer laminated body 40-3is laminated, the claw 24 d (and the claw 24 b) is promptly moved in thevertically lower direction, and presses and holds the newly laminated4-layer laminated body 40-3. When the 4-layer laminated body 40-3 ispressed and held by the claw 24 d (and the claw 24 b), since there is noneed to press and hold the 3-layer laminated body 30-1 and the 4-layerlaminated body 40-2 anymore, the claw 24 c (and the claw 24 a) is movedin the vertically upper direction, then swung around the shaft andwithdrawn from the stage surface 24 g, and stands by above the stagesurface 24 g (withdrawn position).

FIG. 44 illustrates the state where the lamination of the 4-layerlaminated body 40-3 is ended. The 3-layer laminated body 30-1, the4-layer laminated body 40-2 and the 4-layer laminated body 4-3 arepressed and held by the claw 24 d (and the claw 24 b). In addition, theclaw 24 c (and the claw 24 a) is positioned above the stage surface 24 g(withdrawn position) in the standby state, and prepares for thelamination of the 4-layer laminated body to be newly laminated next,that is the 4-layer laminated body sucked and held on the outerperipheral surface of the laminating head 22 b.

In such a manner, according to the arrangement of the claws 24 a-24 dillustrated in FIG. 39, since the two claws other than the clawspressing and holding the laminated body can stand by above the stagesurface 24 g (withdrawn position) without the need of being withdrawn soas not to be obstructive when the next laminated body enters, thelaminated body is promptly pressed and held after it is laminated andthe total lamination time can be shortened.

Note that the outer peripheral surface (holding portion 22 a 3) of thelaminating head 22 a may be configured such that the cross sectionviewed from the circumferential direction of the laminating drum 22 isnot flat and is curved in a concave shape or a convex shape and the3-layer laminated body or the 4-layer laminated body is sucked and heldon the concave or the convex. It is to suppress fluttering of the partof the 3-layer laminated body or the 4-layer laminated body protrudingfrom the end of the laminating head 22 a even in the case where the sizeof the outer peripheral surface of the laminating head 22 a is made onesize smaller than the size of the 3-layer laminated body or the 4-layerlaminated body. In the case where the holding portion 22 a 3 of thelaminating head 22 a is curved in the convex shape, the close positionof the laminating head 22 a and the stage surface 24 g means theposition at which the distance between the most convex part of theholding portion 22 a 3 and the stage surface 24 g is the shortest. Inthe case where the outer peripheral surface of the laminating head 22 ais curved in the concave shape, the close position of the laminatinghead 22 a and the stage surface 24 g means the position at which thedistance between the part positioned at the outermost periphery of thelaminating head 22 a and the stage surface 24 g is the shortest.

The embodiment of the present disclosure has been described above, andthe present disclosure is not limited to the embodiment and can bevarious modified.

Hereinafter, modifications will be described.

<Modification 1>

While only one set of the laminating drum 22 and the laminating stage 24is arranged in the present embodiment, the plurality of sets of thelaminating drum 22 and the laminating stage 24 may be arranged.

FIG. 45 illustrates a configuration diagram in the case of arranging alaminating drum 23 and a laminating stage 25 in addition to thelaminating drum 22 and the laminating stage 24.

The 3-layer laminated body 30 and the 4-layer laminated body 40generated by being cut at the separator cutting drum 20 are supplied tothe laminating drum 22 or the laminating drum 23. The 3-layer laminatedbody 30 and the 4-layer laminated body 40 supplied to the laminatingdrum 22 are successively laminated on the laminating stage 24 arrangedadjacently to the laminating drum 22. In addition, the 3-layer laminatedbody 30 and the 4-layer laminated body 40 supplied to the laminatingdrum 23 are successively laminated on the laminating stage 25 arrangedadjacently to the laminating drum 23.

The laminating drum 22 and the laminating drum 23 are each in contactwith the separator cutting drum 20, and are mutually rotated in the samedirection as the rotation direction of the separator cutting drum 20.The arrangement that the plurality of laminating drums 22 and 23 arerotated in the same direction as a conveyance direction of the 3-layerlaminated body 30 and the 4-layer laminated body 40 conveyed from theseparator cutting drum 20 in such a manner is referred to as a parallelarrangement. In the parallel arrangement, structures of the laminatedbodies laminated on the laminating stages 24 and 25 are identical.

FIG. 46 illustrates the situation of the lamination using the set of thelaminating drum 22 and the laminating stage 24 and the set of thelaminating drum 23 and the laminating stage 25.

The controller which controls the entire manufacturing deviceselectively supplies the 3-layer laminated body 30 and the 4-layerlaminated body 40 generated by being cut at the separator cutting drum20 to one of the laminating drum 22 and the laminating drum 23. Forexample, in the case of first manufacturing the laminated electrodeassembly by performing the lamination on the laminating stage 24 andthen manufacturing the laminated electrode assembly by performing thelamination on the laminating stage 25, the controller supplies the3-layer laminated body 30 and the 4-layer laminated body 40 from theseparator cutting drum 20 to the laminating drum 22 first.

The laminating drum 22 receives the 3-layer laminated body 30 suppliedfrom the separator cutting drum 20 and laminates it on the laminatingstage 24. Then, on the 3-layer laminated body 30, the total of 37 piecesof the 4-layer laminated bodies 40 for example are laminated and onelaminated electrode assembly is manufactured. When the last 37th 4-layerlaminated body 40 is supplied to the laminating drum 22, the controllerswitches an output destination of the separator cutting drum 20 from thelaminating drum 22 to the laminating drum 23.

The laminating drum 23 receives the 3-layer laminated body 30 suppliedfrom the separator cutting drum 20 and laminates it on the laminatingstage 25. Then, on the 3-layer laminated body 30, the total of 37 piecesof the 4-layer laminated bodies 40 for example are laminated and anotherlaminated electrode assembly is manufactured. When the last 37th 4-layerlaminated body 40 is supplied to the laminating drum 23, the controllerswitches the output destination of the separator cutting drum 20 fromthe laminating drum 23 to the laminating drum 22 again.

There is no problem when

the 3-layer laminated body 30, the 4-layer laminated body 40, the4-layer laminated body 40, . . . , the 3-layer laminated body 30, the4-layer laminated body 40, . . . are normally supplied from theseparator cutting drum 20, but there may be a case where abnormalityoccurs in at least one of the negative electrode cutting drum 10, thenegative electrode heating drum 12, the positive electrode cutting drum14, the positive electrode heating drum 16, the bonding drum 18 and theseparator cutting drum 20 and normal 3-layer laminated body 30 and4-layer laminated body 40 are not generated. In such a case, when theabnormality is detected by a detection sensor provided in each drum, the3-layer laminated body 30 or the 4-layer laminated body 40 is eliminatedas a defect before being supplied to the laminating drums 22 and 23, anda normal flow of the laminated bodies that 37 pieces of the 4-layerlaminated bodies 40 follow after one 3-layer laminated body 30 is notmaintained. For example, at the time of generating the 37th 4-layerlaminated body 40, when a bonding defect of the positive electrode platePP is generated at the bonding drum 18 and thus the 37th 4-layerlaminated body 40 is determined as a defect and eliminated in aninspection process of the bonding drum 18, not the 4-layer laminatedbody 40 but the next 3-layer laminated body 30 is supplied for the 37thpiece from the separator cutting drum 20. When the 3-layer laminatedbody 30 is laminated on the laminating stage 24 from the laminating drum22, the normal laminated electrode assembly is not manufactured.

Then, in such a case, it is also possible to supply the 3-layerlaminated body 30 supplied instead of the 37th 4-layer laminated body 40not to the laminating drum 22 but to the laminating drum 23 and make thelaminating drum 23 laminate the 3-layer laminated body 30 on thelaminating stage 25. By supplying the 4-layer laminated body 40 suppliedfrom the separator cutting drum 20 after the 3-layer laminated body tothe laminating drum 22 and laminating it on the laminating stage 24, thelaminated body for which the 37 pieces of the 4-layer laminated bodies40 are laminated on the 3-layer laminated body 30 is formed on thelaminating stage 24.

Note that the laminated body for which the predetermined number of the4-layer laminated bodies 40 are laminated on the 3-layer laminated body30 is pressurized and/or heated, bonded to each other and turned to thelaminated electrode assembly.

FIG. 47 schematically illustrates the lamination method in this case.

The controller monitors the laminated body generated by being cut at theseparator cutting drum 20, identifies whether it is the 3-layerlaminated body 30 or the 4-layer laminated body 40 and also successivelycounts the number of pieces. When the abnormality occurs in the 37th4-layer laminated body 40 and it is eliminated as a defect, the 37thpiece becomes not the 4-layer laminated body 40 but the 3-layerlaminated body 30.

When the 37th laminated body is the 4-layer laminated body 40, thecontroller supplies it to the laminating drum 22, however, when it isdetected that the 37th laminated body is not the 4-layer laminated body40 but the 3-layer laminated body 30, changes the output destination ofthe separator cutting drum 20 from the laminating drum 22 to thelaminating drum 23 and laminates the 3-layer laminated body 30 not onthe laminating stage 24 but on the laminating stage 25. In the figure,an X mark attached to the 3-layer laminated body 30 indicates that it isnot to be laminated on the laminating stage 24 and is to be laminated onthe laminating stage 25. Thereafter, since the 4-layer laminated bodies40 are successively supplied, the controller maintains the outputdestination of the separator cutting drum 20 as the laminating drum 23,and successively laminates the 37 pieces of the 4-layer laminated bodies40 on the laminating stage 25. For the laminating stage 24, bylaminating one 4-layer laminated body 40 in need at an appropriatetiming, the laminated electrode assembly is completed.

By arranging the plurality of sets of the laminating drum and thelaminating stage and appropriately distributing the laminated bodies,even when a defect occurs in the laminated body, the laminated electrodeassembly can be efficiently manufactured without stopping themanufacturing process.

While the defect of the laminated body can be detected at any drum, inorder to detect the defect of the negative electrode plate NP and thedefect of the positive electrode plate PP in particular, the detectionsensor such as a camera is arranged at the negative electrode heatingdrum 12 and the positive electrode heating drum 16 and the defectdetected at the drums can be eliminated. In this case, the negativeelectrode heating drum 12 comprises a normal/defect determinationfunction and a defect elimination function together with a function ofheating the negative electrode plate NP. Similarly, the positiveelectrode heating drum 16 comprises the normal/defect determinationfunction and the defect elimination function together with a function ofheating the positive electrode plate PP.

In the case of detecting the defect on the negative electrode cuttingdrum 10 and the positive electrode cutting drum 14, after the negativeelectrode single plate or the positive electrode single plate is cut,the normal/defect determination function and the defect eliminationfunction are provided. The negative electrode cutting drum 10 and thepositive electrode cutting drum 14 may comprise the normal/defectdetermination function and the negative electrode heating drum 12 andthe positive electrode heating drum 16 may comprise the defectelimination function.

In the case of detecting the defect on the separator cutting drum 20,after the separator is cut and before the cut laminated body is suppliedto the laminating drum, the normal/defect determination function and thedefect elimination function are provided. That is, the separator cuttingdrum 20 comprises the normal/defect determination function and thedefect elimination function together with a function of cutting theseparator.

<Modification 2>

While the laminating drums 22 and 23 are arranged in parallel in FIG.45, the laminating drums 22 and 23 may be arranged in series to theseparator cutting drum 20.

FIG. 48 illustrates the configuration of this case. The 3-layerlaminated body 30 and the 4-layer laminated body 40 generated by beingcut at the separator cutting drum 20 are supplied to the laminating drum22. The laminating drum 23 is arranged in contact with not the separatorcutting drum 20 but the laminating drum 22. To the laminating drum 23,the 3-layer laminated body 30 and the 4-layer laminated body 40 aresupplied via the laminating drum 22. The 3-layer laminated body 30 andthe 4-layer laminated body 40 supplied to the laminating drum 22 aresuccessively laminated on the laminating stage 24 arranged adjacently tothe laminating drum 22. In addition, the 3-layer laminated body 30 andthe 4-layer laminated body 40 supplied to the laminating drum 23 aresuccessively laminated on the laminating stage 25 arranged adjacently tothe laminating drum 23.

The laminating drum 22 and the laminating drum 23 are rotated in themutually different directions. The arrangement that the laminating drums22 and 23 in contact are rotated in the mutually different directions insuch a manner is referred to as a series arrangement. The rotation inthe mutually different directions means the case where one drum isrotated clockwise and the other drum is rotated counterclockwise. In theseries arrangement, the structures of the laminated bodies laminated onthe laminating stages 24 and 25 may be different.

That is, the laminating drum 23 is supplied with the 3-layer laminatedbody 30 and the 4-layer laminated body 40 via the laminating drum 22 incontact, but the rotation direction of the laminating drum 23 isopposite to the rotation direction of the laminating drum 22. The3-layer laminated body 30 and the 4-layer laminated body 40 suppliedfrom the laminating drum 23 to the laminating stage 25 are inverted inregard to the arrangement of the 3-layer laminated body 30 and the4-layer laminated body 40 supplied from the laminating drum 22 to thelaminating stage 24. Then, for example, while the 3-layer laminated bodyis laminated first and the 4-layer laminated bodies are successivelylaminated on the 3-layer laminated body on the laminating stage 24, the4-layer laminated bodies are successively laminated and the 3-layerlaminated body is laminated on the 4-layer laminated body on thelaminating stage 25. Accordingly, in the series arrangement, thestructures of the laminated bodies laminated on the laminating stages 24and 25 may be different.

Note that, when the configuration is such that the laminating drum 23 isnot brought into contact with the laminating drum 22 but an intermediatedrum 27 is interposed to the laminating drum 22 and the laminating drum23 is brought into contact with the intermediate drum 27 as illustratedin FIG. 49, the laminating drum 22 and the laminating drum 23 arerotated in the same direction to the separator cutting drum 20 so thatit is the parallel arrangement.

<Modification 3>

While the present embodiment is the configuration of the negativeelectrode cutting drum 10, the negative electrode heating drum 12, thepositive electrode cutting drum 14, the positive electrode heating drum16, the bonding drum 18, the separator cutting drum 20 and thelaminating drum 22, the negative electrode heating drum 12 may beomitted to adjacently arrange the negative electrode cutting drum 10 andthe bonding drum 18 and the positive electrode heating drum 16 may beomitted to adjacently arrange the positive electrode cutting drum 14 andthe bonding drum 18.

FIG. 50 illustrates the configuration of this case. Differently fromFIG. 1, the negative electrode heating drum 12 and the positiveelectrode heating drum 16 are not provided, the negative electrodecutting drum 10 and the bonding drum 18 are adjacent and the positiveelectrode cutting drum 14 and the bonding drum 18 are adjacent.

The negative electrode cutting drum 10 generates the negative electrodeplate NP by cutting the belt-like negative electrode single plate N,heats the negative electrode plate NP and then supplies it to thebonding drum 18. It can be said that the negative electrode cutting drum10 also has the function of the negative electrode heating drum 12 inFIG. 1.

In addition, the positive electrode cutting drum 14 generates thepositive electrode plate PP by cutting the belt-like positive electrodesingle plate P, heats the positive electrode plate PP and then suppliesit to the bonding drum 18. It can be said that the positive electrodecutting drum 14 also has the function of the positive electrode heatingdrum 16 in FIG. 1.

The negative electrode cutting drum 10 and the bonding drum 18 areadjacent in FIG. 50, however, the negative electrode cutting drum 10 andthe bonding drum 18 may be separated and the heated negative electrodeplate NP from the negative electrode cutting drum 10 may be conveyed tothe bonding drum 18 by a conveyance mechanism such as a belt conveyor.Similarly, the positive electrode cutting drum 14 and the bonding drum18 may be separated and the heated positive electrode plate PP from thepositive electrode cutting drum 14 may be conveyed to the bonding drum18 by a conveyance mechanism such as a belt conveyor.

<Modification 4>

While the belt-like separators S1 and S2 are cut at the separatorcutting drum 20 in the present embodiment, the separator cutting drum 20may be omitted and the belt-like separators S1 and S2 may be cut at thebonding drum 18.

FIG. 51 illustrates the configuration of this case. Differently fromFIG. 1, the separator cutting drum 20 is not provided and the 3-layerlaminated body 30 and the 4-layer laminated body 40 generated by beingcut at the bonding drum 18 are supplied to the laminating drum 22 viathe conveyance mechanism.

The bonding drum 18 comprises a bonding head comprising a round blade,and cuts the belt-like separators S1 and S2 at a predetermined cuttingposition 28. The bonding head may comprise the round blade and a cuttingfunction for example.

<Modification 5>

The 3-layer laminated body and the 4-layer laminated body are created inthe present embodiment, however, without being limited thereto, a2-layer laminated body or the laminated body with the number oflaminations equal to or larger than four can be also created. Forexample, the positive electrode cutting drum 14 and the positiveelectrode heating drum 16 may be eliminated or stopped in FIG. 1 and thenegative electrode plate NP may be supplied onto the separator S1,bonded at the bonding drum 18 and supplied to the separator cutting drum20 as the 2-layer laminated body. The separator S2 may be supplied ontothe negative electrode plate NP, bonded at the bonding drum 18 andsupplied to the separator cutting drum 20 as the 2-layer laminated body.The separator S2 may be supplied onto the negative electrode plate NPand bonded at the bonding drum 18 and the positive electrode plate PPmay be supplied further onto the separator S2, bonded at the bondingdrum 18 and supplied to the separator cutting drum 20 as the 3-layerlaminated body. Or, the laminated body with the number of laminationsequal to or larger than four may be created and supplied to theseparator cutting drum 20 by repeatedly executing the bonding at thebonding drum 18.

<Modification 6>

The separator cutting drum 20 and the laminating drum 22 do not need tobe arranged closely to the bonding drum 18. The laminated body may becreated by laminating the belt-like separator, the positive electrodeand the negative electrode by the method and the device different fromthe bonding drum 18, the belt-like separator may be cut and it may belaminated at the laminating drum 22. On the other hand, the laminatedbody for which the belt-like separator, the positive electrode and thenegative electrode are laminated may be created at the bonding drum 18and the laminated electrode assembly may be created by the method andthe device different from the separator cutting drum 20 and thelaminating drum 22.

REFERENCE SIGNS LIST

-   10 negative electrode cutting drum-   12 negative electrode heating drum-   14 positive electrode cutting drum-   16 positive electrode heating drum-   18 bonding drum-   20 separator cutting drum-   22 laminating drum-   24 laminating stage-   N negative electrode single plate-   P positive electrode single plate-   NP negative electrode plate-   PP positive electrode plate

1. An electrode assembly cutting device, comprising: a plurality ofholding heads arranged in a circumferential direction of a drum androtated around a drum center axis holding a rectangular electrodeassembly; and cutting means provided in each of the plurality of holdingheads and configured to cut the rectangular electrode assembly in apredetermined width, wherein the cutting means comprise a pair of bladesarranged in a thickness direction of the rectangular electrode assemblyso as to hold the rectangular electrode assembly therebetween.
 2. Thecutting device according to claim 1, wherein the pair of bladesmaintains a distance so as not to overlap with each other in thethickness direction of the rectangular electrode assembly and cuts therectangular electrode assembly.
 3. The electrode assembly cutting deviceaccording to claim 2, wherein a distance L of the pair of blades in thethickness direction of the rectangular electrode assembly and athickness d of the electrode assembly satisfy d>L≥0.
 4. The electrodeassembly cutting device according to claim 2, wherein the rectangularelectrode assembly comprises a current collector and an active materiallayer formed on at least one surface of the current collector, and thepair of blades cuts the active material layer and does not cut thecurrent collector.
 5. The electrode assembly cutting device according toclaim 4, wherein the pair of blades forms a cut without cutting thecurrent collector.
 6. The electrode assembly cutting device according toclaim 4, wherein the current collector is cut by tensile stress byrotation of the holding heads.
 7. The electrode assembly cutting deviceaccording to claim 2, wherein the rectangular electrode assemblycomprises a current collector and an active material layer formed on atleast one surface of the current collector, the current collector has acut surface by tensile stress, and the active material layer has a cutsurface by shearing stress.
 8. The electrode assembly cutting deviceaccording to claim 1, wherein the cutting means cut the rectangularelectrode assembly by reciprocating in a width direction of therectangular electrode assembly, which is a direction roughly orthogonalto the circumferential direction of the drum.
 9. The electrode assemblycutting device according to claim 8, wherein a moving surface duringforward movement and a moving surface during return movement in thereciprocation are different from each other.
 10. The electrode assemblycutting device according to claim 9, wherein the cutting means cut therectangular electrode assembly by being moved forward in the widthdirection of the rectangular electrode assembly, which is the directionroughly orthogonal to the circumferential direction of the drum, theholding head holding the cut rectangular electrode assembly is moved ina direction of separating from the holding head holding the rectangularelectrode assembly, and the cutting means are moved back in the widthdirection of the rectangular electrode assembly, which is the directionroughly orthogonal to the circumferential direction of the drum, afterbeing moved in the direction of separating from the rectangularelectrode assembly.
 11. The electrode assembly cutting device accordingto claim 8, wherein each blade of the pair of blades is a rotary roundblade.
 12. The electrode assembly cutting device according to claim 8,wherein each blade of the pair of blades is a rotary round blade with aflat portion formed at one part.
 13. The electrode assembly cuttingdevice according to claim 12, wherein the pair of blades cuts therectangular electrode assembly by round blade portions facing each otherduring forward movement in the reciprocation, and does not come intocontact with the rectangular electrode assembly while the flat portionsface each other during return movement.
 14. A separator cutting device,comprising: a plurality of holding heads arranged in a circumferentialdirection of a drum and rotated around a drum center axis holding abelt-like separator; and cutting means provided in each of the pluralityof holding heads and configured to cut the belt-like separator in apredetermined width, wherein the cutting means comprise a pair of bladesarranged in a thickness direction of the belt-like separator so as tohold the belt-like separator therebetween, and the cutting means cut thebelt-like separator by reciprocating in a width direction of thebelt-like separator, which is a direction roughly orthogonal to thecircumferential direction of the drum.
 15. The separator cutting deviceaccording to claim 14, wherein a moving surface during forward movementand a moving surface during return movement in the reciprocation aredifferent from each other.
 16. The separator cutting device according toclaim 15, wherein the cutting means cut the belt-like separator by beingmoved forward in the width direction of the belt-like separator, whichis the direction roughly orthogonal to the circumferential direction ofthe drum, the holding head holding the cut separator is moved in adirection of separating from the holding head holding the belt-likeseparator, and the cutting means are moved back in the width directionof the belt-like separator, which is the direction roughly orthogonal tothe circumferential direction of the drum, after being moved in thedirection of separating from the belt-like separator.
 17. The separatorcutting device according to claim 14, wherein each blade of the pair ofblades is a rotary round blade.
 18. The separator cutting deviceaccording to claim 17, wherein each blade of the pair of blades is arotary round blade with a flat portion formed at one part.
 19. Theseparator cutting device according to claim 18, wherein the pair ofblades cuts the belt-like separator by round blade portions facing eachother during the forward movement in the reciprocation, and does notcome into contact with the belt-like separator while the flat portionsface each other during the return movement.